Aluminum battery and method for manufacturing the same

Abstract

PURPOSE: To provide an aluminum battery more excellent in product competition power, and a method for manufacturing the same.SOLUTION: An aluminum battery includes a negative electrode structure. The negative electrode structure includes a substrate and an aluminum alloy layer positioned on the substrate. The aluminum alloy layer includes an aluminum element and a non-aluminum element. The content of the aluminum element occupying the aluminum alloy layer is 85 wt.% or more and less than 100 wt.%. The content of the non-aluminum element occupying the aluminum alloy layer is 15 wt.% or less and more than 0 wt.%. There is also provided a method for manufacturing the aluminum battery.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an aluminum battery and a method for manufacturing the same. [Background technology]

[0002] Generally, aluminum batteries are composed of a positive electrode, a negative electrode, a separator, and an electrolyte, and the design of the negative electrode structure often has a significant impact on the performance of the aluminum battery. Therefore, how to design and manufacture a better negative electrode structure and improve the product competitiveness of aluminum batteries has become a challenge. Summary of the Invention [Problem to be solved by the invention]

[0003] One of the challenges is how to design and manufacture a better anode structure and improve the product competitiveness of aluminum batteries. [Means for solving the problem]

[0004] The present invention provides an aluminum battery having superior product competitiveness and a manufacturing method thereof.

[0005] The aluminum battery of the present invention includes a negative electrode structure. The negative electrode structure includes a substrate (aluminum foil or nickel foil) and an aluminum alloy layer located on the substrate. The aluminum alloy layer includes aluminum elements and non-aluminum elements. The content of the aluminum elements in the aluminum alloy layer is 85 wt% or more and less than 100 wt%, and the content of the non-aluminum elements in the aluminum alloy layer is 15 wt% or less and greater than 0 wt%.

[0006] In one embodiment of the present invention, the non-aluminum elements include silicon (Si), magnesium (Mg), nickel (Ni), copper (Cu), zinc (Zn) or a combination thereof.

[0007] In one embodiment of the present invention, the thickness range of the above-mentioned alloy layer is between 50 micrometers and 500 micrometers.

[0008] In one embodiment of the present invention, the aluminum alloy layer described above is composed of solid alloy powder particles of aluminum and non-aluminum elements.

[0009] In one embodiment of the present invention, the average particle size range of the above-mentioned solid alloy powder particles is 10 micrometers to 200 micrometers.

[0010] The manufacturing method of the aluminum battery of the present invention includes: providing a substrate; and performing a thermal spraying process to spray an alloy powder onto the substrate to form an aluminum alloy layer to obtain a negative electrode structure of the aluminum battery.

[0011] In one embodiment of the present invention, after carrying out the above-mentioned thermal spraying process, the alloy powder is sintered and melted, and then sintered and laminated onto a substrate.

[0012] In one embodiment of the present invention, the temperature range of the above-mentioned thermal spraying process is 1000° C. to 2000° C., and the duration of the thermal spraying process is 10 seconds to 120 seconds.

[0013] In one embodiment of the present invention, the method further comprises performing a surface treatment process on the substrate prior to performing the thermal spray process described above. Effect of the Invention

[0014] As described above, the present invention controls the aluminum element and non-aluminum element in the aluminum alloy layer within a suitable weight ratio range through the design of the aluminum alloy layer. In this way, the alloy layer can effectively prevent the formation of an oxide layer on the negative electrode structure, so as to provide the aluminum battery with excellent product competitiveness. In addition, the thermal spraying process has few complicated steps, so as to effectively improve the film-forming speed of the aluminum alloy powder, and in the film-forming process, the temperature to which the substrate surface is heated is relatively low, so as to prevent adverse effects on the substrate. Therefore, by using the aluminum alloy layer formed by the thermal spraying process, the process can be simplified and the process time can be shortened, so as to achieve cost reduction, and at the same time, the quality of the negative electrode structure can be improved, so as to provide the aluminum battery with excellent product competitiveness.

[0015] In order to make the above features and advantages of the present invention more clearly understandable, the following embodiments are given and described in detail in conjunction with the accompanying drawings. [Brief description of the drawings]

[0016] [Figure 1] FIG. 1 is a schematic diagram of an anode structure of an aluminum battery according to one embodiment of the present invention. [Diagram 2] 1 is a flowchart of a method for producing an aluminum battery according to one embodiment of the present invention. [Diagram 3] FIG. 1 is a schematic diagram showing the results of Example 3 under an electron microscope. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] In the following detailed description, for purposes of explanation and not limitation, example embodiments disclosing specific details are set forth in order to provide a thorough understanding of the various principles of the present invention. However, it will be apparent to one skilled in the art having the benefit of the present invention that the present invention may be practiced in other embodiments that depart from the specific details disclosed herein.

[0018] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the drawings. However, the present invention can be implemented in many different forms, and should not be limited to the embodiments described herein. In the drawings, the size and thickness of each region, part, and layer are not drawn based on actual proportions for clarity. For ease of understanding, the same elements are described using the same reference numerals in the following description.

[0019] Directional terms used herein (e.g., up, down, right, left, front, back, upper and lower) are used merely with reference to the drawings and do not imply absolute orientations.

[0020] Unless otherwise defined, all technical terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0021] The term "between" as used herein to define a numerical range includes values ​​equal to and ranges between the recited endpoints. For example, a dimensional range between a first value and a second value means that the dimensional range can include the first value, the second value, and any value between the first and second values.

[0022] FIG. 1 is a schematic diagram of an anode structure of an aluminum battery according to one embodiment of the present invention. FIG. 2 is a flow chart of a method for manufacturing an aluminum battery according to one embodiment of the present invention. Referring to FIG. 1, in the present invention, an aluminum battery includes an anode structure 100, which includes a substrate 110 and an alloy layer 120, and the alloy layer 120 is located on the substrate 110. Here, the substrate 110 is a metal foil material, which is made of, for example, aluminum (Al), nickel (Ni), copper (Cu), titanium (Ti), or other suitable materials, and is preferably an aluminum foil or a nickel foil, and the thickness range of the substrate 110 is 20 micrometers to 500 micrometers.

[0023] In addition, the alloy layer 120 includes aluminum elements and non-aluminum elements, and the content of aluminum elements in the alloy layer 120 is 85wt% or more and less than 100wt%, and the content of non-aluminum elements (e.g., silicon (Si), magnesium (Mg), nickel (Ni), copper (Cu), zinc (Zn)) in the alloy layer 120 is 15wt% or less and greater than 0wt% (so that the alloy layer 120 can be regarded as an aluminum alloy layer). Thus, the present invention controls the aluminum elements and non-aluminum elements therein within a suitable weight ratio range by designing the alloy layer 120. In this way, the alloy layer 120 can be uniformly formed on the negative electrode structure 100, which can provide aluminum batteries with excellent product competitiveness.

[0024] To explain further, in the process of repeatedly charging and discharging an aluminum battery, the electrolyte causes electrochemical deposition on the negative electrode through oxidation and reduction, but a substrate (e.g., a metal aluminum foil) on which an aluminum alloy layer is not formed is easily reactive with oxygen, so that the surface of the substrate is covered with an oxide layer. In this way, the aforementioned oxide layer retards the progress of electrochemical deposition on the surface of the negative electrode, reducing the electrochemical reaction ability of the negative electrode, thereby affecting the performance of the aluminum battery. Therefore, the present invention introduces a design of an aluminum alloy layer 120 that can reduce the generation of an oxide passivation layer, thereby improving the electrochemical deposition reaction ability of the negative electrode structure 100, reducing the deterioration effect of the aforementioned oxide passivation layer on the negative electrode structure 100, and alleviating the problem of metal deposition in the separator, thereby significantly improving the performance of the aluminum battery, but the present invention is not limited thereto.

[0025] In some embodiments, when the non-aluminum elements include silicon (Si), magnesium (Mg), nickel (Ni), copper (Cu), zinc (Zn), or a combination thereof, the silicon (Si) content in the alloy layer 120 (aluminum alloy layer) is about 0.01 wt% to 12 wt%, the magnesium (Mg) content is about 0.01 wt% to 8 wt%, the nickel (Ni) content is about 0.01 wt% to 8 wt%, the copper (Cu) content is about 0.01 wt% to 8 wt%, and the zinc (Zn) content is about 0.01 wt% to 8 wt%.

[0026] In some embodiments, the alloy layer 120 is an aluminum nickel alloy (92 wt% aluminum and 8 wt% nickel) or an aluminum silicon alloy (88 wt% aluminum and 12 wt% silicon), which can provide the anode structure 100 with excellent surface area and corrosion resistance while at the same time providing high stability to the aluminum battery.

[0027] Additionally, the alloy powders described herein may be made by any suitable method, and are not limited by the present invention.

[0028] In this embodiment, the manufacturing method of the aluminum battery can include at least the following steps. Referring to FIG. 2, first, a substrate 110 is provided (step S100), and then a thermal spraying process is performed to spray aluminum alloy powder onto the substrate 110 to form an alloy layer 120 to obtain an aluminum battery anode structure 100 (step S200). The thermal spraying process has few complicated steps, so that the aluminum alloy layer 120 can be formed quickly on the substrate 110 (high-speed film formation), and the temperature to which the surface of the substrate 110 is heated during the film formation process is relatively low (for example, less than 300° C., and as shown in FIG. 1, an intermetallic compound (IMC) 111 can be generated between the aluminum alloy layer 120 and the substrate 110), so that the substrate 110 is not easily adversely affected. Therefore, by using the aluminum alloy layer 120 formed by the thermal spraying process, the manufacturing process time can be simplified and shortened, the cost can be reduced, and at the same time, the quality of the anode structure 100 can be improved, so that the aluminum battery can be provided with excellent product competitiveness.

[0029] To further explain, the negative electrode structure 100 of this embodiment can exhibit excellent charge and discharge performance of aluminum trivalent ions by combining with an aluminum ion electrolyte and a positive electrode system (e.g., graphite), and the negative electrode structure 100 can be obtained by melting aluminum-based powder by a spray method and sintering and laminating it on a substrate (e.g., aluminum foil or nickel foil). In this way, not only can the surface area of ​​the negative electrode body be increased, but the aluminum alloy structure has excellent electrochemical stability, and the intermetallic compound 111 generated at the interface between the substrate 110 and the aluminum alloy layer 120 can effectively improve the charge and discharge performance of the aluminum battery. Therefore, the present embodiment forms a high surface area aluminum alloy layer 120 on the substrate 110 to obtain the negative electrode structure 100 of the aluminum battery. In addition, the atomic lattice in the aluminum alloy layer 120 of this embodiment is suitable for the ingress and egress of aluminum ions, thereby realizing stable charge and discharge performance; the intermetallic compound 111 formed between the aluminum alloy layer 120 and the substrate 110 can prevent the aluminum alloy layer 120 from peeling off and improve the cycle characteristics; and the aluminum alloy layer 120 can effectively suppress the electrolyte from forming an oxide passivation layer on the negative electrode structure, thereby providing aluminum batteries with excellent product competitiveness.

[0030] In some embodiments, when performing the thermal spraying process, the aluminum alloy powder is composed of solid powder particles of aluminum and non-aluminum elements. That is, after the thermal spraying process is completed, the aluminum alloy powder is sintered on the substrate 110 to form an aluminum alloy layer 120 composed of solid powder particles of aluminum and non-aluminum elements, and the thermal spraying process does not adopt a method of making a slurry (the slurry contains additives or adhesives or the like) and then applying and firing it, so that the conductivity of the aluminum alloy layer 120 can be improved, and the performance of the aluminum battery can be further improved. Here, the solid powder particles can have different particle sizes. For example, the average particle size range of the aluminum alloy layer 120 is about 20 microns. That is, the particle sizes of the solid powder particles can be the same or different, but all are within the range of 10 microns to 200 microns. However, the present invention is not limited thereto.

[0031] In addition, since the aluminum alloy powder is composed of solid powder particles, after the thermal spraying process, the aluminum alloy layer 120 is formed in a manner that large and small particles melt and deposit with each other. That is, after the thermal spraying process, the aluminum alloy powder is alternately stacked on the substrate 110, forming voids (high specific surface area) in the aluminum alloy layer 120. In this way, the ability of the electrolyte to infiltrate into the negative electrode structure 100 can be improved, the replenishment speed and infiltration effect of the electrolyte can be increased, and the electrochemical reaction ability of the negative electrode structure 100 can be improved, thereby improving the power capacity performance of the aluminum battery. However, the present invention is not limited thereto.

[0032] In some embodiments, the thermal spraying process uses a high-temperature heat source generated by combustion thermal energy (flame and high-velocity flame) or electrical energy (plasma and arc) to heat the aluminum alloy powder material to a semi-molten state, and then accelerates the semi-molten material by high-pressure gas to collide with the substrate 110, so that a solid aluminum alloy layer 120 is formed upon cooling, and the adhesion of the alloy layer 120 can be improved. Here, the high-pressure gas is, for example, nitrogen gas or argon gas or a mixed gas, and the process pressure is 1-20 kgf / mm 2 Here, the thermal spraying process can be a powder spraying process (thermal process) or a post-treatment process with subsequent thermal calcination.

[0033] In some embodiments, the temperature range of the thermal spraying process is 1000° C. to 2000° C., and the duration of the thermal spraying process is 10 seconds to 120 seconds, which can satisfy the requirements for high-speed film formation properties and simultaneously reduce the requirements for the properties of the substrate 110 (e.g., high temperature resistance, etc.), but the present invention is not limited thereto.

[0034] In some embodiments, the excellent controllability and high-speed deposition characteristics of the thermal spraying process allow the thickness of the aluminum alloy layer 120 to be controlled within a certain thinness range, which can effectively improve the volumetric energy density of the aluminum battery and improve the power capacity and performance. For example, the thickness range of the alloy layer 120 is between 50 micrometers and 500 micrometers, and the thickness of the aluminum alloy layer 120 is more preferably 100 micrometers or less, but the present invention is not limited thereto.

[0035] In some embodiments, before performing the thermal spraying process, the substrate is subjected to a surface treatment process including a cleaning and roughening process, where the cleaning process can be performed by drying to remove moisture from the surface, by using an organic solvent (e.g., ethanol and isopropanol, etc.) to remove grease, or by wiping or cleaning with an air gun to remove contaminants such as dirt and the like, thereby reducing the possibility of adhesion failure and reducing impurities trapped between the substrate 110 and the aluminum alloy layer 120, which can have a negative effect on the interface (influence on IMC generation).

[0036] In some embodiments, before performing the thermal spraying process, the substrate is subjected to a surface roughening process. For example, the surface roughness is increased by methods such as polishing, brushing, or sandblasting, and the surface area is increased by providing the substrate 110 with a surface roughness (e.g., Ra is 1 micrometer to 5 micrometers (μm)). A better mechanical engagement can be obtained when the semi-molten aluminum alloy powder collides with the surface of the substrate 110. Here, the bonding strength of the aluminum alloy sprayed layer (e.g., 3 kgf / mm 2 By further performing an appropriate post-treatment (e.g., a baking process), the bonding strength can be increased to 10 kgf / mm 2 However, the present invention is not limited thereto.

[0037] In some embodiments, the aluminum battery includes a positive electrode, a negative electrode structure 100, a separator, and an electrolyte, where the separator is located between the positive electrode and the negative electrode structure 100, the electrolyte is located between the positive electrode and the negative electrode structure 100, the electrolyte can be an aluminum halide, or other ionic liquids can be selected, and the separator includes glass fiber, but the present invention is not limited thereto.

[0038] The present invention does not limit other components (e.g., positive electrode, separator, and electrolyte) of the aluminum battery and its manufacturing method, as long as the negative electrode structure of the aluminum battery (electrolyte using aluminum-based ions) includes a substrate and an aluminum alloy layer, and the content of aluminum elements in the alloy layer is 85wt% or more and less than 100wt%, and the content of non-aluminum elements in the alloy layer is 15wt% or less and greater than 0wt%, and the manufacturing method of the aluminum battery is to perform a thermal spraying process to spray aluminum alloy powder onto the substrate to form an aluminum alloy layer to obtain the negative electrode structure of the aluminum battery, all of which are within the scope of protection of the present invention. Therefore, in this text, detailed descriptions of other components (e.g., positive electrode, separator, and electrolyte) will be omitted so as not to obscure the understanding of various principles of the present invention.

[0039] The effects of the present invention will be described in more detail below with reference to examples and comparative examples. Although the following examples are described, the details of the materials used and the process may be appropriately changed without departing from the scope of the present invention, and the present invention should not be interpreted as being limited by the following examples.

[0040] Comparative Example 1

[0041] The metal aluminum foil was cut to obtain a negative electrode (thickness 0.05 millimeters (mm), size Φ14 mm). A graphite slurry was applied onto the aluminum foil (thickness 0.05 mm, size Φ14 mm) to obtain a positive electrode. Next, the negative electrode, separator (glass fiber filter paper (Chongqing Olympus Technology Co., Ltd., product name CY-H14)), and positive electrode were arranged in this order, and placed in an electrolysis cell rich in electrolyte (aluminum chloride: 1-ethyl-3-methylimidazolium chloride molar ratio of 1.3:1), to obtain an aluminum battery of Comparative Example 1.

[0042] Comparative Example 2

[0043] The manufacturing method of the aluminum battery of Comparative Example 2 was similar to that of Comparative Example 1, except that the negative electrode was replaced with nickel foil to obtain the aluminum battery of Comparative Example 2.

[0044] Example 1

[0045] This method is similar to the manufacturing method of the aluminum battery of Comparative Example 1, but differs in that the negative electrode is replaced with a negative electrode structure (which may correspond to the structure of FIG. 1A ) in which an aluminum alloy layer is formed on a substrate (aluminum foil) using a thermal spraying process, the thickness of the aluminum alloy layer is 50 micrometers, the aluminum alloy powder used in the thermal spraying process is aluminum silicon alloy powder (Al: 96 wt%; Si: 4 wt%), the high-pressure gas used is nitrogen gas, and the pressure is 6 kgf / mm 2 The treatment time was 60 seconds, and the aluminum battery of Example 1 was obtained.

[0046] Example 2

[0047] The manufacturing method of the aluminum battery of Example 2 is similar to that of Example 1, except that the aluminum silicon alloy powder with a different ratio (Al: 92 wt%; Si: 8 wt%) was used to obtain the aluminum battery of Example 2.

[0048] Example 3

[0049] The manufacturing method of the aluminum battery of Example 3 is similar to that of Example 1, except that the aluminum silicon alloy powder with a different ratio (Al: 88 wt%; Si: 12 wt%) was used to obtain the aluminum battery of Example 3.

[0050] Example 4

[0051] The manufacturing method of the aluminum battery of Example 4 is similar to that of Example 1, except that the aluminum silicon alloy powder with a different ratio (Al: 84 wt%; Si: 16 wt%) was used to obtain the aluminum battery of Example 4.

[0052] Example 5

[0053] This method is similar to the manufacturing method of the aluminum battery of Comparative Example 2, but differs in that the negative electrode is replaced with a negative electrode structure (corresponding to the structure of FIG. 1A) in which an aluminum alloy layer is formed on a substrate (nickel foil) using a thermal spraying process, the thickness of the aluminum alloy layer is 50 micrometers, the aluminum alloy powder used in the thermal spraying process is aluminum silicon alloy powder (Al: 90 wt%; Si: 10 wt%), the high-pressure gas used is nitrogen gas, and the pressure is 6 kgf / mm 2 The treatment time was 60 seconds, and the aluminum battery of Example 5 was obtained.

[0054] Example 6

[0055] The manufacturing method for the aluminum battery of Example 6 is similar to that of Example 1, except that the aluminum alloy powder used was aluminum magnesium alloy powder (Al: 96 wt%; Mg: 4 wt%), and the aluminum battery of Example 6 was obtained.

[0056] Example 7

[0057] The manufacturing method of the aluminum battery of Example 7 is similar to that of Example 6, except that the aluminum magnesium alloy powder with a different ratio (Al: 92 wt%; Mg: 8 wt%) was used to obtain the aluminum battery of Example 7.

[0058] Example 8

[0059] The manufacturing method of the aluminum battery of Example 8 is similar to that of the aluminum battery of Example 6, except that the aluminum magnesium alloy powder with a different ratio (Al: 88 wt%; Mg: 12 wt%) was used to obtain the aluminum battery of Example 8.

[0060] Example 9

[0061] The manufacturing method of the aluminum battery of Example 9 is similar to that of Example 5, except that the aluminum alloy powder used was aluminum magnesium alloy powder (Al: 92 wt%; Mg: 8 wt%), and the aluminum battery of Example 9 was obtained.

[0062] Example 10

[0063] The manufacturing method for the aluminum battery of Example 10 is similar to that of Example 1, except that the aluminum alloy powder used was aluminum-nickel alloy powder (Al: 96 wt%; Ni: 4 wt%), and the aluminum battery of Example 10 was obtained.

[0064] Example 11

[0065] The manufacturing method of the aluminum battery of Example 11 is similar to that of the aluminum battery of Example 10, except that the aluminum-nickel alloy powder with a different ratio (Al: 92 wt%; Ni: 8 wt%) was used to obtain the aluminum battery of Example 11.

[0066] Example 12

[0067] The manufacturing method of the aluminum battery of Example 12 is similar to that of the aluminum battery of Example 10, except that the aluminum-nickel alloy powder with a different ratio (Al: 88 wt%; Ni: 12 wt%) is used to obtain the aluminum battery of Example 12.

[0068] Example 13

[0069] The manufacturing method for the aluminum battery of Example 13 is similar to that of Example 5, except that the aluminum alloy powder used was aluminum-nickel alloy powder (Al: 92 wt%; Ni: 8 wt%), and the aluminum battery of Example 13 was obtained.

[0070] Example 14

[0071] The manufacturing method of the aluminum battery of Example 14 is similar to that of Example 1, except that the aluminum alloy powder used was aluminum-copper alloy powder (Al: 96 wt%; Cu: 4 wt%), and the aluminum battery of Example 14 was obtained.

[0072] Example 15

[0073] The manufacturing method of the aluminum battery of Example 15 is similar to that of the aluminum battery of Example 14, except that the aluminum-copper alloy powder with a different ratio (Al: 92 wt%; Cu: 8 wt%) is used to obtain the aluminum battery of Example 15.

[0074] Example 16

[0075] The manufacturing method of the aluminum battery of Example 16 is similar to that of the aluminum battery of Example 14, except that the aluminum-copper alloy powder with a different ratio (Al: 88 wt%; Cu: 12 wt%) is used to obtain the aluminum battery of Example 16.

[0076] Example 17

[0077] The manufacturing method of the aluminum battery of Example 17 was similar to that of Example 5, except that the aluminum alloy powder used was aluminum-copper alloy powder (Al: 92 wt%; Cu: 8 wt%), to obtain the aluminum battery of Example 17.

[0078] Example 18

[0079] The manufacturing method for the aluminum battery of Example 18 is similar to that of Example 1, except that the aluminum alloy powder used was aluminum-zinc alloy powder (Al: 96 wt%; Zn: 4 wt%), and the aluminum battery of Example 18 was obtained.

[0080] Example 19

[0081] The manufacturing method of the aluminum battery of Example 19 is similar to that of Example 18, except that the aluminum alloy powder used was aluminum-zinc alloy powder (Al: 92 wt%; Zn: 8 wt%), and the aluminum battery of Example 19 was obtained.

[0082] Example 20

[0083] The manufacturing method for the aluminum battery of Example 20 was similar to that of Example 18, except that the aluminum alloy powder used was aluminum-zinc alloy powder (Al: 88 wt%; Zn: 12 wt%), and the aluminum battery of Example 20 was obtained.

[0084] Example 21

[0085] The manufacturing method of the aluminum battery of Example 21 was similar to that of Example 5, except that the aluminum alloy powder used was aluminum-zinc alloy powder (Al: 92 wt%; Zn: 8 wt%), and the aluminum battery of Example 21 was obtained.

[0086] The aluminum batteries of the above-mentioned embodiment and comparative example were subjected to 100 cycles of charge / discharge testing at two C rates, 1C and 3C (difference in performance between slow charge / discharge and fast charge / discharge), and the power capacity (mAh / g) and charge / discharge efficiency (%) of the two batteries were compared to see the difference in reactivity (power capacity) and charge / discharge efficiency (CE). The results are shown in Table 1. As can be seen from Table 1, the aluminum battery of the embodiment is superior to the comparative example in both power capacity and charge / discharge efficiency. In other words, the present invention demonstrates that the introduction of an aluminum alloy layer (such as an aluminum silicon alloy, an aluminum magnesium alloy, an aluminum nickel alloy, an aluminum copper alloy, an aluminum zinc alloy, etc.) having an aluminum element content of 85 wt% or more and less than 100 wt%, and a non-aluminum element content of 15 wt% or less and more than 0 wt%, can provide aluminum batteries with excellent product competitiveness. Also, as can be demonstrated from Figure 3, in the microstructure, it can be observed that after spraying, compared with the flat metal foil material (before spraying), the sprayed alloy is in a powder deposition state (the surface changes to a porous structure with particle deposition). Therefore, the surface area is larger than the original flat surface, which means that the contact area with the electrolyte is increased and more reaction sites are provided. In other words, it helps to improve the contact and infiltration between the electrode and the electrolyte, increase the reaction sites and improve the reactivity.

[0087] It should be mentioned that the composition design of the aluminum nickel alloy coating can improve the electrical properties and corrosion resistance by adding nickel. However, the increase in nickel will increase the melting point of the aluminum alloy, which will cause incomplete melting during the spraying process, and will affect the spray quality due to the decrease in adhesion. Therefore, the nickel content of the composition design of the aluminum nickel alloy coating is more preferably less than 8 wt% in Examples 11 and 13, but the present invention is not limited thereto. Furthermore, the composition design of the aluminum silicon alloy coating can improve the binding strength and electrical properties of the coating by adding silicon. However, the increase in silicon will reduce the melting point of the aluminum alloy, which will cause the temperature during the spraying process to be too high, resulting in complete melting, scorching the powder, and reducing the spray quality. Therefore, the silicon content of the composition design of the aluminum silicon alloy coating is more preferably less than 12 wt% in Example 3, but the present invention is not limited thereto.

[0088] [Table 1]

[0089] Other compositions and specifications of the aluminum battery not described herein can be obtained by a person skilled in the art to which the present invention pertains based on the contents within the spirit and scope of the appended claims.

[0090] As described above, the present invention controls the aluminum element and non-aluminum element in the aluminum alloy layer within a suitable weight ratio range through the design of the aluminum alloy layer. In this way, the aluminum alloy layer can improve the charge-discharge cycle characteristics and effectively inhibit the formation of an oxide passivation layer on the negative electrode structure, so as to provide the aluminum battery with excellent product competitiveness. In addition, the thermal spraying process has fewer complicated steps, so as to effectively improve the film formation speed, and in the film formation process, the surface of the substrate is heated to a relatively low temperature, so as to be less likely to cause adverse effects on the substrate. Therefore, the aluminum alloy layer formed by the thermal spraying process can optimize the quality of the negative electrode structure and provide the aluminum battery with an excellent electrochemical application life.

[0091] Although the present invention has been disclosed by the above embodiments, these are not intended to limit the present invention, and a person having ordinary knowledge in the art can make some changes and modifications without departing from the spirit and scope of the present invention, and therefore the scope of protection of the present invention is defined by the claims below. [Industrial Applicability]

[0092] The aluminum battery and its manufacturing method can be applied to the aluminum battery field. [Explanation of symbols]

[0093] 100 negative electrode structure 110 Substrate 111 Intermetallic compounds 120 alloy layer S100, S200 Step

Claims

1. 1. An aluminum battery comprising: A substrate; an aluminum alloy layer located on the substrate; a negative electrode structure including %と100wt%。 Aluminum alloy layer contains aluminum and non-aluminum elements, the content of the aluminum element in the aluminum alloy layer is 85 wt% or more and less than 100 wt%, and the content of the non-aluminum elements in the aluminum alloy layer is 15 wt% or less and more than 0 wt%.

2. 2. The aluminum battery of claim 1, wherein the non-aluminum elements include silicon, magnesium, nickel, copper, zinc, or a combination thereof.

3. 2. The aluminum battery according to claim 1, wherein the thickness range of the aluminum alloy layer is between 50 micrometers and 500 micrometers.

4. 2. The aluminum battery according to claim 1, wherein said aluminum alloy layer is composed of solid alloy powder particles of said aluminum element and said non-aluminum element.

5. 5. The aluminum battery according to claim 4, wherein the solid alloy powder particles have an average particle size range of 10 micrometers to 200 micrometers.

6. A method for manufacturing an aluminum battery, comprising: Providing a substrate; Carrying out a thermal spraying process to spray aluminum alloy powder onto the substrate to form an aluminum alloy layer to obtain the aluminum battery negative electrode structure; A method for producing an aluminum battery, comprising:

7. The method for manufacturing an aluminum battery according to claim 6, wherein after the thermal spraying process is performed, the aluminum alloy powder is melted and sintered and laminated on the substrate.

8. The method for manufacturing an aluminum battery according to claim 6, wherein after the thermal spraying process is performed, the aluminum alloy powder is layered alternately on the substrate.

9. the temperature range of the thermal spray process is 1000°C to 2000°C; The method for manufacturing an aluminum battery according to claim 6, wherein the thermal spraying process is carried out for a period of time ranging from 10 seconds to 120 seconds.

10. The method for manufacturing an aluminum battery according to claim 6, further comprising carrying out a surface treatment process on the substrate before carrying out the thermal spraying process.

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