Aluminum battery and method for manufacturing the same

Abstract

The present invention provides an aluminum battery including an electrode structure and a method for manufacturing the same. [Solution] An aluminum battery including an electrode structure is provided. The electrode structure includes a substrate and a channel layer located on the substrate. The channel layer is made of aluminum chloride. An aluminum battery and a method for manufacturing the same are also provided.

Description

Technical Field

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

Background Art

[0002] Generally, an aluminum battery consists of a positive electrode, a negative electrode, a separator, and an electrolyte. However, the design of these elements often significantly affects the performance of the aluminum battery (such as charge and discharge efficiency).

Summary of the Invention

Problems to be Solved by the Invention

[0003] An aluminum battery consists of a positive electrode, a negative electrode, a separator, and an electrolyte. However, the design of these elements often significantly affects the performance of the aluminum battery (such as charge and discharge efficiency).

Means for Solving the Problems

[0004] The present invention provides an aluminum battery and a method for manufacturing the same that can effectively improve the performance of the aluminum battery.

[0005] The aluminum battery of the present invention includes an electrode structure. The electrode structure includes a base material and a channel layer located on the base material. The material of the channel layer includes aluminum chloride.

[0006] In one embodiment of the present invention, the above aluminum battery further includes an electrolyte. The electrode structure is disposed in the electrolyte, and the electrolyte includes aluminum ions, chloride ions, sodium ions, nitrogen ions, or a combination thereof.

[0007] [[ID=4 1]]In one embodiment of the present invention, the thickness range of the above channel layer is between 2 micrometers and 20 micrometers.

[0008] In one embodiment of the present invention, the electrode structure further includes an intermediate layer, the intermediate layer being located between the substrate and the channel layer.

[0009] In one embodiment of the present invention, the channel layer is partially embedded within the intermediate layer.

[0010] In one embodiment of the present invention, the electrode structure is a negative electrode structure, and the intermediate layer contains an aluminum alloy.

[0011] In one embodiment of the present invention, the electrode structure is a positive electrode structure, and the intermediate layer contains aluminum carbide.

[0012] The present invention relates to a method for manufacturing an aluminum battery, which includes manufacturing an electrode structure. Manufacturing the electrode structure includes providing a substrate and performing a chlorination treatment to form a channel layer on the substrate, wherein the material of the channel layer includes aluminum chloride.

[0013] In one embodiment of the present invention, the method further includes performing a spray coating step to form an intermediate layer on the substrate before performing the chlorination treatment step described above.

[0014] In one embodiment of the present invention, the step of performing the chlorination treatment includes immersion treatment, and the immersion treatment includes immersing the substrate in saline solution. [Effects of the Invention]

[0015] Based on the above, the electrode structure of the present invention introduces a channel layer containing aluminum chloride as an ion channel structure, allowing other ions to enter smoothly, thereby helping the active substance react more smoothly and effectively improving the performance of the aluminum battery.

[0016] To highlight the above-mentioned features and advantages of the present invention, embodiments are described below in detail with reference to the accompanying drawings. [Brief explanation of the drawing]

[0017] [Figure 1A] It is a schematic diagram of the electrode structure of an aluminum battery according to an embodiment of the present invention. [Figure 1B] It is a schematic diagram of the lattice structure of aluminum chloride. [Figure 1C] It is a flowchart of a method for manufacturing an aluminum battery according to an embodiment of the present invention. [Figure 1D] It is a schematic diagram of the surface morphology and elemental analysis of an aluminum foil without undergoing immersion treatment. [Figure 1E] It is a schematic diagram of the surface morphology and elemental analysis of an aluminum foil after being immersed in pure water. [Figure 1F] It is a schematic diagram of the surface morphology and elemental analysis of an aluminum foil after being immersed in saturated saline. [Figure 2A] It is a schematic cross-sectional view of manufacturing a negative electrode structure by a method for manufacturing an aluminum battery according to an embodiment of the present invention. [Figure 2B] It is a schematic cross-sectional view of manufacturing a negative electrode structure by a method for manufacturing an aluminum battery according to an embodiment of the present invention. [Figure 2C] It is a schematic cross-sectional view of manufacturing a negative electrode structure by a method for manufacturing an aluminum battery according to an embodiment of the present invention. [Figure 3A] It is a schematic cross-sectional view of a positive electrode structure in a method for manufacturing an aluminum battery according to an embodiment of the present invention. [Figure 3B] It is a schematic cross-sectional view of a positive electrode structure in a method for manufacturing an aluminum battery according to an embodiment of the present invention. [Figure 3C] It is a schematic cross-sectional view of a positive electrode structure in a method for manufacturing an aluminum battery according to an embodiment of the present invention.

Mode for Carrying Out the Invention

[0018] In the following detailed description, for purposes of illustration and not limitation, exemplary embodiments are set forth in which specific details are disclosed in order to provide a thorough understanding of the various principles of the invention. It will be apparent to those skilled in the art that the invention may be practiced in other embodiments that depart from the specific details disclosed herein.

[0019] Exemplary embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different forms and should not be construed as being limited to the embodiments described herein. In the drawings, for the sake of clarity, the sizes and thicknesses of various regions, components, and layers may not be drawn to actual scale. The same or similar reference numerals represent the same or similar elements and will not be described in detail in the following paragraphs.

[0020] The terms used herein to indicate directions (such as up, down, right, left, front, back, top, bottom, etc.) are for the sole purpose of referring to the drawings and do not indicate absolute directions.

[0021] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art.

[0022] The term "between" used herein to define a numerical range is intended to include the endpoint values and the range between the above endpoint values. For example, when a size range is between a first value and a second value, it means that the size range can include the first value, the second value, and any value between the first value and the second value.

[0023] In this specification, an aluminum battery includes an electrode structure, a separator, and an electrolyte. Here, the electrode structure and the separator are placed in the electrolyte, and the electrode structure may be a collective term for a positive electrode structure and a negative electrode structure. The present invention can effectively improve the performance of an aluminum battery by improving its electrode structure, and in some embodiments, the electrode structure has a synergistic effect with the electrolyte, further optimizing the performance of the aluminum battery. The design and manufacturing methods of the electrode structure and electrolyte in an aluminum battery will be described in detail below with reference to the drawings. The separator can be placed between the electrode structures using any suitable material known to those skilled in the art (e.g., glass fiber and nonwoven fabric), and the present invention is not limited thereto, so it will not be repeated in this specification.

[0024] Figure 1A is a schematic diagram of the electrode structure of an aluminum battery according to one embodiment of the present invention. Figure 1B is a schematic diagram of the lattice structure of aluminum chloride. Figure 1C is a flow chart of the manufacturing method of an aluminum battery according to one embodiment of the present invention. Figure 1D is a schematic diagram of the surface morphology and elemental analysis of aluminum foil without immersion treatment. Figure 1E is a schematic diagram of the surface morphology and elemental analysis of aluminum foil after immersion in pure water. Figure 1F is a schematic diagram of the surface morphology and elemental analysis of aluminum foil after immersion in saturated saline solution.

[0025] Referring to Figure 1A, the electrode structure 100 of the aluminum battery in this embodiment includes a substrate 110 and a channel layer 120. Here, the channel layer 120 is located on the substrate 110. Furthermore, the material of the channel layer 120 includes aluminum chloride, such as aluminum trichloride (AlCl3). This is a compound of chlorine and aluminum, and its structure is Al 3+ This is a cubic close-packed layered structure, or a 6-coordinate layered lattice structure (as shown in Figure 1B). The gaps created by the interlayer spacing in this lattice structure function as ion channels, allowing other ions to enter smoothly, which helps the active material react more smoothly and thereby effectively improves the performance of the aluminum battery.

[0026] In some embodiments, depending on the actual design requirements, the electrode structure 100 further includes an intermediate layer, an intermetallic compound (IMC) layer, and / or an oxide layer (not shown in Figure 1A, but further described in Figures 2B-2C and 3B-3C). For example, one of the three may be present, two may be present, or all three may be present. If all three are present, the intermediate layer is located between the substrate 110 and the channel layer 120, the intermetallic compound layer is located between the substrate 110 and the intermediate layer, and the oxide layer is located on the channel layer 120, but the present invention is not limited thereto.

[0027] In some embodiments, the thickness range of the channel layer 120 is between 2 micrometers and 20 micrometers to provide sufficient space as an ion channel, but the present invention is not limited thereto.

[0028] On the other hand, the substrate 110 and the intermediate layer may have any suitable thickness, and the present invention is not limited thereto. The thickness of the intermetallic compound layer and / or oxide layer is generally negligibly thin, but the thickness of the oxide layer may be thicker. In such cases, the thickness range is, for example, between 0.01 micrometers and 0.1 micrometers, but the present invention is not limited thereto.

[0029] In this embodiment, the method for manufacturing an aluminum battery may include at least the following steps (steps for manufacturing the electrode structure 100). Referring to Figure 1C, first, a substrate 110 is provided (step S100). Next, a chlorination treatment is performed to form a channel layer 120 on the substrate 110 (step S110), thereby effectively improving the charge and discharge efficiency of the electrode structure 100.

[0030] In some embodiments, the chlorination process may include, for example, immersion in saline solution (NaCl) of the substrate 110. As shown in Figures 1D to 1F, when the substrate 110 (aluminum foil) is immersed in pure water, no chlorine or sodium elements are formed on the surface. On the other hand, when the substrate 110 (aluminum foil) is immersed in saline solution, chlorine and sodium elements are formed on the surface. Therefore, it is confirmed that immersion in saline solution generates a chloride film layer on the substrate 110 (aluminum foil). It should be noted that Figures 1D to 1F do not limit the present invention; that is, it is known to those skilled in the art that similar results can be obtained when the immersion tests in Figures 1D to 1F are performed on different suitable substrates 110 or similar structures.

[0031] In some embodiments, when an aluminum battery is assembled with an electrode structure 100 and a suitable electrolyte (for example, a liquid electrolyte consisting of aluminum chloride and 1-ethyl-3-methylimidazolium chloride or a similar configuration), the electrolyte contains aluminum ions, chloride ions, sodium ions, nitrogen ions or a combination thereof, and these ions can more effectively increase the interatomic layer spacing between the channel layer 120 (aluminum chloride) and other layers, thereby optimizing the electrical performance of the aluminum battery (for example, obtaining a higher electrical capacity), but the present invention is not limited thereto.

[0032] In some embodiments, the concentration range of the saline solution is between approximately 0.9% (e.g., physiological saline solution) and 36% (e.g., saturated saline solution), but the present invention is not limited thereto.

[0033] In some embodiments, hydrochloric acid (1 M concentration) may be dropped onto the intermediate layer 120 after the immersion treatment. In this way, the immersion time can be shortened by approximately five times, and the manufacturing speed of the electrode structure 100 can be improved. During the manufacturing process, the electrode structure 100 needs to be covered with hydrochloric acid, and the electrodes may be properly washed with clean water and dried, but the present invention is not limited thereto.

[0034] In some embodiments, when hydrochloric acid is not used in subsequent steps, the immersion time is at least 60 minutes to further ensure the generation of chloride and sodium ions, but the present invention is not limited thereto.

[0035] In some embodiments, a washing step (e.g., using pure water) and / or a drying step may be performed after the immersion treatment. Therefore, in the process of manufacturing the electrode structure 100 of this embodiment, only the steps of immersion in saline solution, washing, and / or drying are required. Compared to organic solvents, ionic liquids, or electroplating solutions (including organic salts), which are highly hazardous and difficult to handle, saline solution, which does not contain heavy metals, strong acids, strong bases, or organic solvents, only needs to be diluted with clean water before discharge, and does not require further neutralization of acidity or alkalinity or disposal using special waste methods. Furthermore, electroplating is now often used for surface modification of metals. The toxicity of electroplating solutions poses a danger to workers in the process stage, and special treatment such as appropriate recycling is required for the final wastewater treatment to avoid residual heavy metal substances harming the environment. Recycling work during the process also requires additional energy. On the other hand, in this embodiment, the process design of immersion in saline solution avoids the use of environmentally risky methods while simultaneously achieving the effect of performance improvement. Therefore, this embodiment can be adapted to the trends of carbon reduction and the development of green technologies.

[0036] In some embodiments, the process further includes a spray coating step to form an intermediate layer on the substrate 110 before the chlorination step. Performing the spray coating step allows for the initial acquisition of a stable electrode with excellent initial stability, charge-discharge characteristics, and cycle characteristics, but the present invention is not limited thereto.

[0037] In some embodiments, aluminum batteries do not contain sulfur-containing organisms (non-aluminum sulfur batteries), but the present invention is not limited thereto. It is known to those skilled in the art that the operating mechanism of aluminum sulfur batteries differs from that of non-aluminum sulfur batteries (e.g., the present invention), and therefore will not be described in detail herein.

[0038] In some embodiments, the aluminum battery operates at room temperature, meaning it is not a high-temperature battery (for example, a battery with an operating temperature above 50°C), but the present invention is not limited thereto.

[0039] The following describes a specific embodiment in which the electrode structure is the negative electrode structure 200, with reference to Figures 2A to 2C. Here, since the contents of the electrode structure 100 described in Figures 1A and 1B can all be applied to the negative electrode structure 200, some of the contents are omitted here. Figures 2A to 2C are schematic cross-sectional views of the negative electrode structure in a method for manufacturing an aluminum battery according to one embodiment of the present invention.

[0040] Referring to Figure 2A, first, the base material 210 is provided (corresponding to step S100). Here, the material of the base material 210 as the negative electrode structure 200 may be a metal foil made of, for example, aluminum (Al), nickel (Ni), copper (Cu), titanium (Ti), or other conductive and suitable material that allows for the adhesion of a spray coating.

[0041] Referring to Figure 2B, in this embodiment, a hot spray coating step or a cold spray coating step may be performed as needed to form an intermediate layer 230 on the substrate 210. Here, the intermediate layer 230 material as the negative electrode structure 200 may contain aluminum and non-aluminum elements. The hot spray coating step or the cold spray coating step may be a process and apparatus well known to those skilled in the art and will not be described in detail herein.

[0042] In some embodiments, the aluminum content in the intermediate layer 230 is 85% by weight or more and less than 100% by weight, and the content of elements other than aluminum (e.g., silicon (Si), magnesium (Mg), nickel (Ni), copper (Cu), zinc (Zn)) in the alloy layer 120 is 15% by weight or less and greater than 0% by weight (therefore, the intermediate layer 230 can be considered an aluminum alloy layer).

[0043] In some embodiments, when elements other than aluminum include silicon (Si), magnesium (Mg), nickel (Ni), copper (Cu), zinc (Zn), or a combination thereof, the silicon (Si) content in the intermediate layer 120A is approximately 0.01% to 12% by weight, the magnesium (Mg) content is approximately 0.01% to 8% by weight, the nickel (Ni) content is approximately 0.01% to 8% by weight, the copper (Cu) content is approximately 0.01% to 8% by weight, and the zinc (Zn) content is approximately 0.01% to 8% by weight, but the present invention is not limited thereto.

[0044] In some embodiments, the intermediate layer 230 is an aluminum-nickel alloy (92% aluminum, 8% nickel) or an aluminum-silicon alloy (88% aluminum, 12% silicon), and these aluminum alloys can improve the surface area and corrosion resistance of the negative electrode structure 200 while simultaneously improving the stability of the aluminum battery, but the present invention is not limited thereto.

[0045] In some embodiments, when the intermediate layer 230 is an aluminum alloy layer and the base material 210 is aluminum foil, an aluminum compound layer can be formed after the spray coating process because the alloy powder contains elements other than aluminum, that is, an intermetallic compound layer 240 can be formed between the base material 210 and the intermediate layer 230, but the present invention is not limited thereto.

[0046] Referring to Figure 2C, a chlorination treatment is then performed on the substrate 210 (and intermediate layer 230) to form a channel layer 220 (corresponding to step S110). In this embodiment, the synergistic effect of the intermediate layer 230 (e.g., a spray-coated layer) and the channel layer 220 containing aluminum chloride can more effectively improve the performance of the aluminum battery, but the present invention is not limited thereto. In other embodiments, if the intermediate layer 230 is omitted, an electrode structure consisting of the substrate 210 and the channel layer 220 containing aluminum chloride placed thereon can also effectively improve the performance of the aluminum battery. Furthermore, in some embodiments, if the intermediate layer 230 contains an active metal, drying the chlorinated electrode in an air environment can spontaneously form a dense oxide layer 250 (e.g., an aluminum oxide layer) on the surface of the channel layer 220, but the present invention is not limited thereto.

[0047] In some embodiments, if the electrolyte contains sodium ions and nitrogen ions, they can penetrate the space between the oxide layer 250 and the atomic layer of the channel layer 220 in the negative electrode structure 200, thereby improving the charge-discharge efficiency.

[0048] In some embodiments, when the material of the intermediate layer 230 is a porous material, after immersion treatment, saline solution penetrates into the pores, so that a portion of the channel layer 220 is formed within the pores, and the channel layer 220 is partially embedded within the intermediate layer 230 (as shown in the enlarged portion of Figure 2C). This design allows for an effective increase in the surface area of ​​the channel layer 220, thereby improving subsequent electrical performance, but the present invention is not limited thereto.

[0049] The specific embodiments of the positive electrode structure 300 will be further described below with reference to Figures 3A to 3C. Here, since the contents of the electrode structure 100 described in Figures 1A and 1B can all be applied to the positive electrode structure 300, some of the contents will be omitted here. Figures 3A to 3C are schematic cross-sectional views of a positive electrode structure manufactured by a manufacturing method for an aluminum battery according to one embodiment of the present invention.

[0050] Referring to Figure 3A, first, a substrate 310 is provided (corresponding to step S100). Here, the substrate 310 material as the positive electrode structure 300 may be, for example, nickel foil or a metal foil made of a suitable material that is conductive and allows for the adhesion of a spray coating. Next, a carbon material layer 360 (as an active substance) is formed on the substrate 310 by coating. Here, the material of the carbon material layer 360 includes a graphite layer or a conductive carbon layer.

[0051] Referring to Figure 3B, in this embodiment, a hot spray coating process or a cold spray coating process is then performed to form an intermediate layer 330 on the substrate 310. Here, the hot spray coating process or the cold spray coating process may be a process apparatus well known to those skilled in the art and will not be described in detail in this specification.

[0052] In some embodiments, the substrate 310 may be nickel foil, and the hot spray coating step or cold spray coating step may involve spraying a mixed powder consisting of pure aluminum powder and graphite powder. In this way, the aluminum powder and graphite powder form aluminum carbide (Al4C3: a compound produced by the reaction of aluminum and carbon in the spraying step) at the spraying temperature (e.g., 1000°C or higher), and an aluminum-nickel intermetallic compound layer 340 can be formed between the substrate 310 and the intermediate layer 330. Note that all aluminum powders described herein are pure aluminum powders (non-aluminum alloy powders), and this will not be explained again below.

[0053] In some embodiments, when the amount of graphite powder used exceeds 5% by weight, dispersibility problems tend to occur, resulting in poor spray coating effect. Therefore, the mixing ratio of the mixed powder consisting of aluminum powder and graphite powder may be in the range of 95% by weight:5% by weight or a smaller ratio of graphite powder used, but the present invention is not limited thereto.

[0054] Referring to Figure 3C, a chlorination treatment is then performed to form a channel layer 320 on the substrate 310 (and intermediate layer 330) (corresponding to step S110). In some embodiments, when the intermediate layer 330 contains an active metal, drying the chlorinated electrode in an air environment can spontaneously form a dense oxide layer 350 (e.g., an aluminum oxide layer) on the surface of the channel layer 320, but the present invention is not limited thereto.

[0055] In some embodiments, when the electrolyte contains sodium and nitrogen ions, they can enter the space between the atomic layers of the oxide layer 350 and the channel layer 320 (e.g., reaction equation "aluminum chloride + graphite + aluminum carbide → NaAlCl4 + NaAl4C3") in the positive electrode structure 300, thereby improving the charge-discharge efficiency. For example, in Figure 3C, the channel layer 320 containing aluminum chloride formed by chlorination treatment, the intermediate layer 330 containing graphite powder, and the aluminum carbide formed in the spray coating process react with the electrolyte containing sodium and nitrogen ions that enter the structure, and the sodium or nitrogen ions bind to the aluminum chloride and aluminum carbide, maintaining the smoothness of the maintenance ion channel (the sodium or nitrogen ions are located in the space between the atomic layers, supporting the structure and making it less prone to collapse), thereby improving the charge-discharge efficiency.

[0056] In some embodiments, when the material of the intermediate layer 330 is a porous material, after immersion treatment, saline solution penetrates into the pores, causing a portion of the channel layer 320 to form within the pores, and the channel layer 320 is partially embedded within the intermediate layer 330 (similar to the embedded portion in Figure 2C). This design effectively increases the surface area of ​​the channel layer 320, thereby improving subsequent electrical performance, but the present invention is not limited thereto.

[0057] The effects of the present invention will be further explained below with reference to examples and comparative examples. While embodiments are described below, details such as the materials and processes used can be modified as appropriate without departing from the scope of the present invention. Therefore, the present invention should not be interpreted as being limited by the embodiments described below.

[0058] Negative electrode structures of Examples 1 to 10

[0059] In Example 1, a metallic aluminum foil (substrate) with a thickness of 50 micrometers and a size of Φ14 mm was used as the negative electrode structure. In Examples 3, 5, 7, and 9, an intermediate layer (aluminum alloy layer) was formed on the metallic aluminum foil using a hot spray coating process. Here, the thickness of the intermediate layer was 50 micrometers, and aluminum alloy powder was used in the hot spray coating process, nitrogen was used as the high-pressure gas, and the pressure was 6 kgf / mm². 2 The processing time was set to 60 seconds. The aluminum alloy powders used in Examples 3, 5, 7, and 9 were aluminum-silicon alloy powder (Al: 96% by weight; Si: 4% by weight), aluminum-silicon alloy powder (Al: 92% by weight; Si: 8% by weight), aluminum-silicon alloy powder (Al: 88% by weight; Si: 12% by weight), and aluminum-silicon alloy powder (Al: 84% by weight; Si: 16% by weight), respectively.

[0060] Furthermore, the negative electrode structures of Examples 1, 3, 5, 7, and 9 were subjected to further chlorination treatment (metallic aluminum foil was immersed in saturated saline solution for 30 minutes), the residual saline solution was washed off with pure water, and then dried in an oven at 60°C for 8 hours to obtain the negative electrode structures of Examples 2, 4, 6, 8, and 10, each containing an aluminum chloride negative electrode.

[0061] Negative electrode structures of Examples 11 to 16

[0062] The negative electrode structures of Examples 11, 13, and 15 are the same as those of Examples 3, 5, and 7. The difference is that the aluminum alloy powders used in Examples 11, 13, and 15 are aluminum-magnesium alloy powder (Al: 96% by weight; Mg: 4% by weight), aluminum-magnesium alloy powder (Al: 92% by weight; Mg: 8% by weight), and aluminum-magnesium alloy powder (Al: 88% by weight; Mg: 12% by weight), respectively.

[0063] Furthermore, the negative electrode structures of Examples 11, 13, and 15 were subjected to further chlorination treatment (metallic aluminum foil was immersed in saturated saline solution for 30 minutes), the residual saline solution was washed off with pure water, and then dried in an oven at 60°C for 8 hours to obtain the negative electrode structures of Examples 12, 14, and 16, respectively.

[0064] Negative electrode structures of Examples 17 to 22

[0065] The negative electrode structures of Examples 17, 19, and 21 are the same as those of Examples 3, 5, and 7. The difference is that the aluminum alloy powders used in Examples 17, 19, and 21 are aluminum-nickel alloy powder (Al: 96% by weight; Ni: 4% by weight), aluminum-nickel alloy powder (Al: 92% by weight; Ni: 8% by weight), and aluminum-nickel alloy powder (Al: 88% by weight; Ni: 12% by weight), respectively.

[0066] Furthermore, the negative electrode structures of Examples 17, 19, and 21 were subjected to further chlorination treatment (metallic aluminum foil was immersed in saturated saline solution for 30 minutes), the residual saline solution was washed off with pure water, and then dried in an oven at 60°C for 8 hours to obtain the negative electrode structures of Examples 18, 20, and 22, respectively.

[0067] Negative electrode structures of Examples 23 to 28

[0068] The negative electrode structures of Examples 23, 25, and 27 are the same as those of Examples 3, 5, and 7. The difference is that the aluminum alloy powders used in Examples 23, 25, and 27 are aluminum-copper alloy powder (Al: 96% by weight; Cu: 4% by weight), aluminum-copper alloy powder (Al: 92% by weight; Cu: 8% by weight), and aluminum-copper alloy powder (Al: 88% by weight; Cu: 12% by weight), respectively.

[0069] Furthermore, the negative electrode structures of Examples 23, 25, and 27 were subjected to further chlorination treatment (metallic aluminum foil was immersed in saturated saline solution for 30 minutes), the residual saline solution was washed off with pure water, and then dried in an oven at 60°C for 8 hours to obtain the negative electrode structures of Examples 24, 26, and 28, respectively.

[0070] Negative electrode structures of Examples 29 to 34

[0071] The negative electrode structures of Examples 29, 31, and 33 are the same as those of Examples 3, 5, and 7. The difference is that the aluminum alloy powders used in Examples 29, 31, and 33 are aluminum zinc alloy powder (Al: 96% by weight; Zn: 4% by weight), aluminum zinc alloy powder (Al: 92% by weight; Zn: 8% by weight), and aluminum zinc alloy powder (Al: 88% by weight; Zn: 12% by weight), respectively.

[0072] Furthermore, the negative electrode structures of Examples 29, 31, and 33 were subjected to further chlorination treatment (metallic aluminum foil was immersed in saturated saline solution for 30 minutes), the residual saline solution was washed off with pure water, and then dried in an oven at 60°C for 8 hours to obtain the negative electrode structures of Examples 30, 32, and 34, respectively.

[0073] Aluminum batteries of Examples 1 to 34

[0074] A graphite slurry (without aluminum powder) was applied to nickel foil (thickness 0.05 mm, size Φ14 mm) to obtain a positive electrode structure. Next, the negative electrode structure (Examples 1 to 34), separator (glass fiber filter paper), and positive electrode structure were arranged in order and placed in an electrolytic cell rich in electrolyte (molar ratio of aluminum chloride to 1-ethyl-3-methylimidazolium chloride was 1.3:1) to obtain aluminum batteries of Examples 1 to 34.

[0075] Positive electrode structures of Examples 35 to 41

[0076] For the positive electrode structure of Example 35, a metallic nickel foil (substrate) with a thickness of 0.05 mm and a size of Φ14 mm was used, and a graphite slurry (without aluminum powder) was applied. For the positive electrode structures of Examples 36, 38, and 40, an intermediate layer was formed on the metallic nickel foil using a hot spray coating process. Here, the thickness of the intermediate layer was 50 micrometers, and a mixed powder of aluminum powder and graphite powder was used in the hot spray coating process, nitrogen was used as the high-pressure gas, and the pressure was 6 kgf / mm². 2 The processing time was set to 60 seconds. In Example 36, a mixed powder of aluminum powder (98% by weight) and graphite powder (2% by weight) was used; in Example 38, a mixed powder of aluminum powder (95% by weight) and graphite powder (5% by weight) was used; and in Example 40, a mixed powder of aluminum powder (93% by weight) and graphite powder (7% by weight) was used.

[0077] Furthermore, the positive electrode structures of Examples 36, 38, and 40 were subjected to further chlorination treatment (metallic aluminum foil was immersed in saturated saline solution for 30 minutes), the residual saline solution was washed off with pure water, and then dried in an oven at 60°C for 8 hours to obtain the positive electrode structures of Examples 37, 39, and 41, respectively.

[0078] Aluminum batteries of Examples 35 to 41

[0079] The positive electrode structures from Examples 35 to 41 and the negative electrode structure from Example 6 were used. Next, the negative electrode structure, separator (glass fiber filter paper), and positive electrode structure were arranged in order and placed in an electrolytic cell rich in electrolyte (the molar ratio of aluminum chloride to 1-ethyl-3-methylimidazolium chloride was 1.3:1) to obtain the aluminum batteries of Examples 35 to 41.

[0080] Aluminum batteries of Examples 42 to 48

[0081] The positive electrode structures from Examples 35 to 41 and the negative electrode structure from Example 14 were used. Next, the negative electrode structure, separator (glass fiber filter paper), and positive electrode structure were arranged in order and placed in an electrolytic cell rich in electrolyte (the molar ratio of aluminum chloride to 1-ethyl-3-methylimidazolium chloride was 1.3:1) to obtain the aluminum batteries of Examples 42 to 48.

[0082] Aluminum batteries of Examples 49 to 55

[0083] The positive electrode structures from Examples 35 to 41 and the negative electrode structure from Example 20 were used. Next, the negative electrode structure, separator (glass fiber filter paper), and positive electrode structure were arranged in order and placed in an electrolytic cell rich in electrolyte (the molar ratio of aluminum chloride to 1-ethyl-3-methylimidazolium chloride was 1.3:1) to obtain the aluminum batteries of Examples 49 to 55.

[0084] Aluminum batteries of Examples 56 to 62

[0085] The positive electrode structures from Examples 35 to 41 and the negative electrode structure from Example 26 were used. Next, the negative electrode structure, separator (glass fiber filter paper), and positive electrode structure were arranged in order and placed in an electrolytic cell rich in electrolyte (the molar ratio of aluminum chloride to 1-ethyl-3-methylimidazolium chloride was 1.3:1) to obtain the aluminum batteries of Examples 56 to 62.

[0086] Aluminum batteries of Examples 63 to 69

[0087] The positive electrode structures from Examples 35 to 41 and the negative electrode structure from Example 32 were used. Next, the negative electrode structure, separator (glass fiber filter paper), and positive electrode structure were arranged in order and placed in an electrolytic cell rich in electrolyte (the molar ratio of aluminum chloride to 1-ethyl-3-methylimidazolium chloride was 1.3:1) to obtain the aluminum batteries of Examples 63 to 69.

[0088] The aluminum batteries of Examples 1 to 10 were subjected to 100 charge-discharge cycles under 12V / 10min / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in performance between slow and fast charge / discharge). Comparing the capacity (mAh / g) and charge / discharge Coulomb efficiency (%) of the two, differences in reactivity (capacity) and charge / discharge efficiency (CE) were observed, as shown in Table 1. As can be seen from Table 1, chlorination treatment can improve the performance of aluminum batteries.

[0089] [Table 1]

[0090] The aluminum batteries of Examples 1-2 and Examples 11-16 were subjected to 100 charge-discharge cycles under 12V / 10mim / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in performance between slow and fast charge / discharge). Comparing the capacity (mAh / g) and charge / discharge Coulomb efficiency (%) of the two, differences in reactivity (capacity) and charge / discharge efficiency (CE) were observed, as shown in Table 2. As can be seen from Table 2, chlorination treatment can improve the performance of aluminum batteries.

[0091] [Table 2]

[0092] The aluminum batteries of Examples 1-2 and Examples 17-22 were subjected to 100 charge-discharge cycles under 12V / 10mim / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in performance between slow and fast charge / discharge). Differences in capacity (mAh / g), charge / discharge efficiency (%), reactivity (capacity), and charge / discharge Coulomb efficiency (CE) between the two were observed, and the results are shown in Table 3. As can be seen from Table 3, chlorination treatment can improve the performance of aluminum batteries.

[0093] [Table 3]

[0094] The aluminum batteries of Examples 1-2 and Examples 23-28 were subjected to 100 charge-discharge cycles under 12V / 10mim / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in performance between slow and fast charge / discharge). Comparing the capacity (mAh / g) and charge / discharge Coulomb efficiency (%) of the two, differences in reactivity (capacity) and charge / discharge efficiency (CE) were observed, as shown in Table 4. As can be seen from Table 4, chlorination treatment can improve the performance of aluminum batteries.

[0095] [Table 4]

[0096] The aluminum batteries of Examples 1-2 and Examples 29-34 were subjected to 100 charge-discharge cycles under 12V / 10mim / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in performance between slow and fast charge / discharge). Comparing the capacity (mAh / g) and charge / discharge Coulomb efficiency (%) of the two, differences in reactivity (capacity) and charge / discharge efficiency (CE) were observed, as shown in Table 5. As can be seen from Table 5, chlorination treatment can improve the performance of aluminum batteries.

[0097] [Table 5]

[0098] The aluminum batteries of Examples 35-41 were subjected to 100 charge-discharge cycles under 12V / 10mim / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in low-speed and high-speed charge-discharge performance). Comparing the capacity (mAh / g) and charge-discharge Coulomb efficiency (%) of the two, differences in reactivity (capacity) and charge-discharge efficiency (CE) were observed, as shown in Table 6. As can be seen from Table 6, chlorination treatment can improve the performance of aluminum batteries, and the amount of graphite powder used affects the bonding of the aluminum powder and the battery performance.

[0099] [Table 6] JPEG2026047083000008.jpg45160

[0100] The aluminum batteries of Examples 42-48 were subjected to 100 charge-discharge cycles under 12V / 10mim / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in low-speed and high-speed charge-discharge performance). Comparing the capacity (mAh / g) and charge-discharge Coulomb efficiency (%) of the two, differences in reactivity (capacity) and charge-discharge efficiency (CE) were observed, as shown in Table 7. As can be seen from Table 7, chlorination treatment can improve the performance of aluminum batteries, and the amount of graphite powder used affects the bonding of the aluminum powder and the battery performance.

[0101] [Table 7] JPEG2026047083000010.jpg45160

[0102] The aluminum batteries of Examples 49-55 were subjected to 100 charge-discharge cycles under 12V / 10mim / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in low-speed and high-speed charge-discharge performance). Comparing the capacity (mAh / g) and charge-discharge Coulomb efficiency (%) of the two, differences in reactivity (capacity) and charge-discharge efficiency (CE) were observed, as shown in Table 8. As can be seen from Table 8, chlorination treatment can improve the performance of aluminum batteries, and the amount of graphite powder used affects the bonding of the aluminum powder and the battery performance.

[0103] [Table 8] JPEG2026047083000012.jpg45160

[0104] The aluminum batteries of Examples 56-62 were subjected to 100 charge-discharge cycles under 12V / 10mim / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in low-speed and high-speed charge-discharge performance). Comparing the capacity (mAh / g) and charge-discharge Coulomb efficiency (%) of the two, differences in reactivity (capacity) and charge-discharge efficiency (CE) were observed, as shown in Table 9. As can be seen from Table 9, chlorination treatment can improve the performance of aluminum batteries, and the amount of graphite powder used affects the bonding of the aluminum powder and the battery performance.

[0105] [Table 9] JPEG2026047083000014.jpg45160

[0106] The aluminum batteries of Examples 63-69 were subjected to 100 charge-discharge cycles under 12V / 10mim / 0.05mAh conditions, using two different C rates (1C and 3C) (differences in low-speed and high-speed charge-discharge performance). Comparing the capacity (mAh / g) and charge-discharge Coulomb efficiency (%) of the two, differences in reactivity (capacity) and charge-discharge efficiency (CE) were observed, as shown in Table 10. As can be seen from Table 10, chlorination treatment can improve the performance of aluminum batteries, and the amount of graphite powder used affects the bonding of the aluminum powder and the battery performance.

[0107] [Table 10] JPEG2026047083000016.jpg45160

[0108] In summary, the electrode structure of the present invention introduces a channel layer containing aluminum chloride as an ion channel structure, allowing other ions to enter smoothly. This helps the active substance react more smoothly, thereby effectively improving the performance of the aluminum battery.

[0109] Although the present invention has been disclosed through embodiments as described above, this does not limit the invention. Those with ordinary skill in the art can make some changes and modifications without departing from the spirit and scope of the invention. Therefore, the scope of protection of the present invention shall be determined by the scope of the appended patent application. [Industrial applicability]

[0110] Aluminum batteries can be used in the field of aluminum batteries. [Explanation of symbols]

[0111] 100: Electrode structure 110, 210, 310: Base material 120, 220, 320: Channel Layers 200:Negative electrode structure 230, 330: Middle class 240, 340: Intermetallic compound layer 250, 350: Oxide layer 300: Positive electrode structure 360: Carbon material layer S100, S110: Process

Claims

1. Substrate and Located on the aforementioned substrate, the material comprises a channel layer containing aluminum chloride, An aluminum battery, including an electrode structure.

2. It further contains electrolyte, The electrode structure is placed in the electrolyte, and the electrolyte contains aluminum ions, chloride ions, sodium ions, nitrogen ions, or a combination thereof. The aluminum battery according to claim 1.

3. The thickness range of the channel layer is between 2 micrometers and 20 micrometers. The aluminum battery according to claim 1.

4. The electrode structure further includes an intermediate layer, the intermediate layer being located between the substrate and the channel layer. The aluminum battery according to claim 1.

5. The channel layer is partially embedded within the intermediate layer. The aluminum battery according to claim 4.

6. The electrode structure is a negative electrode structure, and the intermediate layer contains an aluminum alloy. The aluminum battery according to claim 4.

7. The electrode structure is a positive electrode structure, and the intermediate layer contains aluminum carbide. The aluminum battery according to claim 4.

8. To provide a base material, Chlorination treatment is performed to form a channel layer on the substrate, and the material of the channel layer contains aluminum chloride, and the chlorination treatment is performed. A method for manufacturing an aluminum battery, including the manufacture of an electrode structure containing [a specific component].

9. The process further includes performing a spray coating step to form an intermediate layer on the substrate before performing the chlorination treatment step, A method for manufacturing an aluminum battery according to claim 8.

10. The chlorination treatment step includes immersion treatment, and the immersion treatment includes immersing the substrate in saline solution. A method for manufacturing an aluminum battery according to claim 8.

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