Modular aluminum hybrid battery cell with integrated double electrode consisting of a solid intercalation cathode and a gas-reactive air cathode in a flat sandwich design

Abstract

Battery cell with aluminum anode and double electrode, wherein the double electrode comprises an inner, solid intercalation cathode and an outer, gas-reactive air cathode, characterized by its flat to round, modularly stackable shape.

Description

[0001] The present invention combines for the first time an aluminum anode with a compact double electrode consisting of: 1. Internal intercalation electrode, e.g. based on coated metal substrates with graphite or graphene, for the reversible uptake of aluminum complex ions (e.g. AlCl4). - ). 2. External air cathode, designed as an activated carbon-coated, hydrophobized surface with defined air access for the reduction of ambient oxygen. 3. Separate sandwich structure made of flat materials that can be stacked or arranged modularly.

[0002] This results in a hybrid cell with combined discharge options: on the one hand via aluminum-graphite intercalation, and on the other hand via parallel oxygen reduction at the air cathode. The cell is preferably designed as a flat disk cell or modular cell and is specifically optimized for limited installation spaces, e.g., in electric vehicles.

[0003] The cell is designed for an expected number of up to 10,000 charge and discharge cycles. Even after this number of cycles, the remaining capacity is expected to be at least 95% of its original value. This corresponds to a potential lifespan of more than 10 years with daily charging, making the technology particularly attractive for long-lasting, low-maintenance energy storage solutions.

[0004] Furthermore, this invention solves the problem of the availability of so-called "rare earth elements" and is entirely designed for the supply of raw materials within the territory of the Federal Republic of Germany. No imports from other countries are required.

Claims

[1] Battery cell with aluminium anode and double electrode, wherein the double electrode comprises an inner, solid intercalation cathode and an outer, gas-reactive air cathode, characterized by its flat to round, modularly stackable shape. [2] Battery cell according to claim 1, wherein the intercalation electrode is based on a metallic support and includes a coating of graphite, graphene or carbon composite. [3] Battery cell according to claims 1 and 2, wherein the metallic support consists of open-pore metal foam, [4] Battery cell according to claims 1-3, wherein the air cathode contains a hydrophobic activated carbon layer with PTFE binder and is connected to the ambient atmosphere via a semipermeable window (“membrane”). [5] Modular battery system consisting of multiple cells according to claims 1-4, wherein the cells are mechanically stacked and electrically connected in series and / or parallel without additional cables. [6] Battery according to claims 1-5, wherein the terminals are directly formed from the metal foam by mechanical forming (e.g. pressing, punching, rolling) into the shape of a cable and / or mounting object. The externally insulated part is overmolded with plastic by injection molding and is externally indistinguishable from a normal cable / battery terminal.