GAS REDUCTION FOR BATTERY SYSTEMS

Abstract

This disclosure relates to systems and methods for mitigating hydrogen sulfide. A battery cell or a plurality of battery cells in a battery pack having a sulfur-containing lithium-based rechargeable battery component is disclosed. A monolith hydrolyzes hydrogen sulfide gas precipitated by moisture exposure to the sulfur-based cathode to sulfur dioxide and water and releases the sulfur dioxide and water outside the battery cell.

Description

FIELD OF TECHNOLOGY

[0001] This disclosure relates to methods for mitigating by-products for a battery pack. BACKGROUND

[0002] The lithium-sulfur (Li-S) battery exhibits promising theoretical specific energy and availability. However, one challenge associated with lithium-sulfur batteries is the potential formation of hydrogen sulfide (H2S) gas when exposed to water or moisture. This is due to the interaction between the sulfide-based solid-state electrolyte or the sulfur cathode and moisture, resulting in the generation of H2S. The release of H2S can reduce the performance and longevity of the battery systems. SUMMARY

[0003] In one aspect of the disclosure, a sulfur-containing rechargeable lithium-based battery cell is presented. The sulfur-containing rechargeable lithium-based battery cell includes a solid electrolyte sandwiched between an anode and a cathode. The battery cell further includes a monolith configured to hydrolyze hydrogen sulfide gas precipitated by moisture exposure to the cathode into sulfur dioxide and water and to release the sulfur dioxide and water outside the battery cell. The monolith may include a plurality of channels extending therethrough. The channels within the plurality of channels may be arranged to allow direct passage of gases in a flow-through configuration. The plurality of channels may be arranged to allow gases to pass through porous walls in a wall-flow configuration.The monolith may contain catalyst material. The monolith may contain a plurality of channels coated with the catalyst material and extending therethrough. The catalyst material may be Ni / Ce, Cu / zeolite, or Fe / zeolite, singly or in combination. The solid electrolyte may be an inorganic solid electrolyte, a solid polymer electrolyte, a composite polymer electrolyte, a sulfur-based solid electrolyte, or lithium.

[0004] In another aspect of the disclosure, a battery cell is set forth. The sulfur-containing lithium-based rechargeable battery cell comprises a plurality of sulfur-containing lithium-based rechargeable battery cells. The sulfur-containing lithium-based rechargeable battery cell further comprises a monolith configured to hydrolyze hydrogen sulfide gas precipitated by moisture exposure to the plurality of sulfur-containing lithium-based rechargeable battery cells into sulfur dioxide and water and to release sulfur dioxide and water outside the battery pack. The monolith may include a plurality of channels extending therethrough. The channels may be arranged to allow direct passage of gases in a flow-through configuration. The channels are arranged to allow gases to pass through porous walls in a wall-flow configuration.The monolith may contain catalyst material. The monolith may have a plurality of channels coated with the catalyst material and extending therethrough. The catalyst material may be Ni / Ce, Cu / zeolite, or Fe / zeolite, singly or in combination. The solid electrolyte may be an inorganic solid electrolyte, a solid polymer electrolyte, a composite polymer electrolyte, a sulfur-based solid electrolyte, or lithium.

[0005] In yet another aspect of the disclosure, a method is set forth comprising a first step of passing hydrogen sulfide gas precipitated by moisture exposure of a plurality of sulfur-containing rechargeable lithium-based battery cells through channels of a monolith configured to hydrolyze the hydrogen sulfide gas to sulfur dioxide and water, and releasing the sulfur dioxide and water outside the plurality of sulfur-containing rechargeable lithium-based battery cells. The channels within the monolith may be arranged in a through-flow configuration to allow direct passage of gases. The channels within the monolith may be arranged in a wall-flow configuration to allow gases to pass through porous walls.The directing step may include using a blower or pump to facilitate the flow of hydrogen sulfide gas through the monolith. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a representation of an experimental setup; Fig. Figure 2A is a table of sensor readings for control samples; Fig. Figure 2B is a graph of sensor measurements for control samples; Fig. 3A is a table of sensor readings for catalyst materials tested for use with any one or more embodiments of the disclosure; Fig. 3B is a graph of sensor readings for catalyst materials tested for use with any one or more embodiments of the disclosure; Fig. 4 is a schematic view of a battery pack according to an embodiment of the disclosure; Fig. 5 is a schematic view of a battery cell according to an embodiment of the disclosure; Fig. 6A and Fig. 6B are monolith configurations according to one or more embodiments of the disclosure; and Fig. 7 is a flow diagram of a method according to an embodiment of the disclosure. DETAILED DESCRIPTION

[0006] Embodiments are described in this specification. It should be understood, however, that the disclosed embodiments are merely examples, and other embodiments may take various and alternative forms. The figures are not necessarily to scale. Some features may be exaggerated or reduced to show details of specific components. Therefore, specific structural and functional details disclosed in this specification are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art.

[0007] Various features illustrated and described with respect to any of the figures may be combined with features illustrated in one or more other figures to produce embodiments not explicitly illustrated or described. The illustrated combinations of features provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of this disclosure may be desirable for particular applications or implementations.

[0008] Effective management of hydrogen sulfide (H2S) can increase the efficiency of battery systems, especially those using lithium-sulfur technology. H2S, a potential byproduct formed by the interaction of sulfur-based battery components with moisture, poses significant challenges to both the performance and reliability of battery systems. To effectively mitigate any potential performance impacts on the battery, the adoption of catalytic materials is proposed. Among these, Ni / Ce, Cu / zeolite, and Fe / zeolite, when used individually, in combination, or with other catalysts, have demonstrated potential for their effectiveness in absorbing and converting H2S gas.

[0009] The approach of using monolith catalysts to mitigate H2S within battery packs is presented. The catalysts can be located at the battery pack outlet to maximize exposure to the evolved H2S gas under both normal and non-normal operating conditions. An exemplary monolith catalyst configuration can include multiple channels through which the gas flows from the inlet to the outlet. This configuration can facilitate direct contact between the flowing gas and the catalysts coated on the channel surfaces. Catalytic reactions occur to convert the H2S into hydrogen and sulfur.The incorporation of active materials into the monolith catalyst can be achieved by coating the surface of the monolith substrate, which is typically extruded from cordierite, or by mixing the active materials with the substrate prior to extrusion, resulting in a multi-channel monolith structure.

[0010] In an effort to understand the efficiency and functionality of different catalysts in absorbing H2S, an experimental setup was constructed as described in Fig. 1. This setup aimed to closely replicate the conditions under which these catalysts would operate in a battery pack environment, focusing on their ability to mitigate H2S emissions. In the experiment, a gas source was used to mix H2S with laboratory air, delivering it through a reactor at a concentration of 5 parts per million (ppm) and a flow rate of 1000 ml / min. This reactor, measuring 1 inch in diameter and 1 inch in length, was exposed to the gas mixture and then connected to a sensor designed to measure the emitted H2S levels after reactor interaction. The experimental setup also included the use of a video camera to continuously record the H2S sensor readings and the corresponding time, allowing the creation of a graph of H2S versus time for each test condition.

[0011] Before introducing any catalyst materials into the reactor, a background test was conducted using a bare reactor setup to establish a baseline for H2S emissions. This was followed by individual tests for each of the selected catalyst materials: Ni / Ce, Cu / zeolite, and Fe / zeolite. The results from the background tests, as described in Fig. 2A and Fig. As illustrated in Figure 2B, H2S measurements of 82.7 and 83.3 ppm were recorded after 57 and 47 seconds, respectively, indicating the presence of H2S in the absence of a catalyst. In contrast, the conversion of catalyst materials in the reactor showed a reduction in H2S emissions. As shown in Fig. 3A and Fig. As can be seen in Figure 3B, the presence of Ni / Ce and Cu / zeolite catalysts within the reactor material resulted in minimal H2S readings at the sensor even after extended periods of gas release. This difference highlights the effectiveness of these catalysts in absorbing H2S under test conditions set to closely replicate room-temperature environments. Both Ni / Ce and Cu / zeolite demonstrated the ability to effectively absorb H2S at room temperature, as evidenced by the minimal H2S readings recorded after the gas passed through reactors containing these catalysts. Fe / zeolite was found to be less effective at absorbing H2S under the same temperature conditions. The choice of the selected catalyst can be influenced by the environmental conditions of the deposition site and the desired results.

[0012] With reference to Fig. 4-5 is Fig. 4 is a schematic view of a battery pack 10 with a monolith 12. The battery pack 10 has individual cells 14. As in Fig. 5, each of the individual cells 14 within the battery pack 10 is a sulfur-containing lithium-based rechargeable battery cell having a solid electrolyte 16 enclosed between an anode 18 and a cathode 20. The solid electrolyte 16 may be any compatible electrolyte, such as an inorganic solid electrolyte (ISE), a solid polymer electrolyte (SPE), or a composite polymer electrolyte (CPE). The monolith 12 is configured to mitigate the generation of hydrogen sulfide gas, a byproduct of moisture interaction with the cathode 20. The monolith 12 is configured to do this by incorporating catalyst materials 22 that hydrolyze hydrogen sulfide gas to sulfur dioxide and water. The sulfur dioxide and water are then released outside the battery cell 14 or the battery pack 10.External mitigation of hydrogen sulfide can help preserve the integrity and lifetime of the cell. The catalyst materials 22 that can be used are Ni / Ce, Cu / zeolite, Fe / zeolite, individually or in combination, to facilitate the hydrolysis of hydrogen sulfide gas to sulfur dioxide and water. The incorporation of catalyst materials 22 into the monolith 12 can be accomplished by extruding the catalyst materials 22 with a substrate material 24, such as cordierite. The substrate material 24 can also be coated with catalyst materials 22.

[0013] The monolith 12 may have channels 26 as shown in Fig. 6A and Fig. 6B, and the channels 26 may be configured in different ways to optimize the gas treatment process within the battery pack 10. Fig. Figure 6A illustrates a monolith configuration 28 in which the monolith 12 includes the plurality of channels 26 extending therethrough. These channels 26 are structured to enable a direct flow-through configuration, allowing gases to pass directly through the channels 26 to maintain efficient gas movement and reaction within the monolith 12. Fig. Figure 6B shows a configuration 30 in which the channels 26 within the monolith 12 are configured to allow gases to pass through porous walls 32 in a wall-flow configuration. This arrangement can be effective in maximizing the contact area between the hydrogen sulfide gas and the catalyst materials 22 coated along the channels 26, which affects the hydrolysis process.

[0014] Fig.7 illustrates a flow diagram of a method 34 for mitigating H2S in lithium-sulfur batteries according to one aspect of the disclosure. In block 36, hydrogen sulfide gas precipitated by moisture exposure of a plurality of sulfur-containing rechargeable lithium-based battery cells is passed through channels of a monolith configured to hydrolyze the hydrogen sulfide gas to sulfur dioxide and water. In block 38, the sulfur dioxide and water are released outside the plurality of sulfur-containing rechargeable lithium-based battery cells. The channels within the monolith may be arranged in a flow-through configuration to allow direct passage of gases. Alternatively, the channels within the monolith may be arranged in a wall-flow configuration to allow gases to pass through porous walls.In some embodiments, the step of directing may include using a blower or pump to facilitate flow of hydrogen sulfide gas through the monolith.

[0015] The algorithms, methods, or processes disclosed in this document may be executable by or implemented by a computer, controller, or processing device, which may include any dedicated electronic control unit or programmable electronic control unit. Furthermore, the algorithms, methods, or processes may be stored in many forms as computer- or controller-executable data and instructions, including, but not limited to, information permanently stored on non-writable storage media, such as read-only memory devices, and information modifiably stored on writable storage media, such as compact discs, random access memory devices, or other magnetic and optical media. The algorithms, methods, or processes may also be implemented in software-executable objects.Alternatively, the algorithms, methods, or processes may be implemented in whole or in part using suitable hardware components, such as application-specific integrated circuits, field-programmable gate arrays, state machines, or other hardware components or devices, or a combination of firmware, hardware, and software components.

[0016] While exemplary embodiments are described above, these embodiments are not intended to describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosed subject matter.

[0017] As previously described, the features of various embodiments may be combined to form further embodiments of the disclosure that may not be explicitly described or illustrated. While various embodiments may have been described as providing advantages or being preferred over other prior art embodiments or implementations with respect to one or more desired characteristics, one of ordinary skill in the art will understand that one or more features or characteristics may be compromised to achieve desired overall system attributes depending on the specific application and implementation. These attributes may include, but are not limited to, strength, durability, marketability, appearance, installation, size, serviceability, weight, manufacturability, ease of assembly, etc.Thus, embodiments that are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.

[0018] According to the present invention, a battery cell is provided, comprising: a sulfur-containing lithium-based rechargeable battery; and a monolith configured to hydrolyze hydrogen sulfide gas precipitated by moisture exposure to the cathode into sulfur dioxide and water and to release the sulfur dioxide and water outside the sulfur-containing lithium-based rechargeable battery cell.

[0019] According to one embodiment, the monolith includes a plurality of channels extending therethrough.

[0020] According to one embodiment, the channels are arranged to allow direct passage of gases in a flow-through configuration.

[0021] According to one embodiment, the channels are arranged to allow gases to pass through porous walls in a wall flow configuration.

[0022] According to one embodiment, the monolith contains catalyst material.

[0023] According to one embodiment, the monolith includes a plurality of channels coated with the catalyst material and extending therethrough.

[0024] According to one embodiment, the catalyst material is, individually or in combination, Ni / Ce, Cu / zeolite and Fe / zeolite.

[0025] According to one embodiment, the solid electrolyte is selected from the group consisting of an inorganic solid electrolyte, a solid polymer electrolyte, a composite polymer electrolyte, a sulfur-based solid electrolyte, and lithium.

[0026] According to the present invention, a battery pack is provided, comprising: a plurality of sulfur-containing rechargeable lithium-based battery cells; and a monolith configured to hydrolyze hydrogen sulfide gas precipitated by moisture exposure to the plurality of battery cells into sulfur dioxide and water and to release sulfur dioxide and water outside the battery pack.

[0027] According to one embodiment, the monolith includes a plurality of channels extending therethrough.

[0028] According to one embodiment, the channels are arranged to allow direct passage of gases in a flow-through configuration.

[0029] According to one embodiment, the channels are arranged to allow gases to pass through porous walls in a wall flow configuration.

[0030] According to one embodiment, the monolith contains catalyst material.

[0031] According to one embodiment, the monolith includes a plurality of channels coated with the catalyst material and extending therethrough.

[0032] According to one embodiment, the catalyst material is, individually or in combination, Ni / Ce, Cu / zeolite and Fe / zeolite.

[0033] According to one embodiment, the solid electrolyte is selected from the group consisting of an inorganic solid electrolyte, a solid polymer electrolyte, a composite polymer electrolyte, a sulfur-based solid electrolyte, and lithium.

[0034] According to the present invention, the method includes: passing hydrogen sulfide gas precipitated by moisture exposure to a plurality of sulfur-containing rechargeable lithium-based battery cells through channels of a monolith configured to hydrolyze the hydrogen sulfide gas to sulfur dioxide and water; and releasing the sulfur dioxide and water outside the plurality of sulfur-containing rechargeable lithium-based battery cells.

[0035] In one aspect of the invention, the channels within the monolith are arranged in a flow-through configuration to allow direct passage of gases.

[0036] In one aspect of the invention, the channels within the monolith are arranged in a wall flow configuration to allow gases to pass through porous walls.

[0037] In one aspect of the invention, directing includes using a blower or pump to facilitate flow of hydrogen sulfide gas through the monolith.

Claims

[1] Solid-state battery cell, comprising: a solid electrolyte enclosed between a lithium-based anode and a sulfur-based cathode; and a monolith configured to hydrolyze hydrogen sulfide gas precipitated by moisture exposure to the sulfur-based cathode to sulfur dioxide and water and to release the sulfur dioxide and water outside the solid-state battery cell. [2] The solid-state battery cell of claim 1, wherein the monolith includes a plurality of channels extending therethrough. [3] A solid-state battery cell according to claim 2, wherein the channels are arranged to allow direct passage of gases in a flow-through configuration. [4] A solid-state battery cell according to claim 2, wherein the channels are arranged to allow gases to pass through porous walls in a wall-flow configuration. [5] A solid-state battery cell according to claim 1, wherein the monolith includes catalyst material. [6] A solid-state battery cell according to claim 5, wherein the monolith includes a plurality of channels coated with the catalyst material and extending therethrough. [7] A solid-state battery cell according to claim 5, wherein the catalyst material is Ni / Ce, Cu / zeolite or Fe / zeolite singly or in combination. [8] The all-solid-state battery cell according to claim 1, wherein the solid electrolyte is selected from the group consisting of an inorganic solid electrolyte, a solid polymer electrolyte, a composite polymer electrolyte, a sulfur-based solid electrolyte, and lithium. [9] Battery pack comprising: a variety of solid-state lithium-sulfur battery cells; and a monolith configured to hydrolyze hydrogen sulfide gas precipitated by moisture exposure to the plurality of solid-state lithium-sulfur battery cells into sulfur dioxide and water and to release sulfur dioxide and water outside the battery pack. [10] The battery pack of claim 9, wherein the monolith includes a plurality of channels extending therethrough. [11] A battery pack according to claim 10, wherein the channels are arranged to allow direct passage of gases in a flow-through configuration. [12] A battery pack according to claim 10, wherein the channels are arranged to allow gases to pass through porous walls in a wall flow configuration. [13] The battery pack of claim 9, wherein the monolith includes catalyst material. [14] The battery pack of claim 13, wherein the monolith includes a plurality of channels coated with the catalyst material and extending therethrough. [15] A battery pack according to claim 13, wherein the catalyst material is Ni / Ce, Cu / zeolite or Fe / zeolite alone or in combination.

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