Anode-Less Sodium Cell with In-Situ Metal Anode Formation
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Solution Overview
Problem
Existing sodium-based secondary batteries face challenges due to lower energy density, manufacturing difficulties, and reliance on critical minerals like nickel and cobalt, limiting their commercial success and sustainability.
Innovation Solution
Development of sodium electrochemical cells with an in-situ formed sodium metal anode, utilizing a bare metal current collector and non-aqueous electrolytes, enabling an anode-less design that maximizes energy density and minimizes the use of critical minerals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If sodium-based secondary batteries use traditional cathode materials with nickel and cobalt, then energy density can be improved, but cost and sustainability deteriorate due to reliance on critical minerals
Solution Approach 1:
The patent extracts and eliminates nickel and cobalt from the cathode material composition, developing sodium-based cathode materials that achieve high energy density without these critical minerals. This is accomplished by optimizing the cathode structure and composition to rely solely on sodium and more abundant, cost-effective elements.
Solution Approach 2:
The patent changes the chemical composition parameters of the cathode material by substituting nickel and cobalt with alternative elements while maintaining or improving energy density. This involves adjusting stoichiometric ratios, oxidation states, and material phases to achieve optimal performance without critical minerals.
2Quantity of substance
If sodium-based secondary batteries use higher atomic weight sodium materials, then material abundance and cost are improved, but energy density deteriorates due to lower operating voltage
Solution Approach 1:
The patent develops composite cathode materials that combine sodium-based compounds with other elements to create a synergistic structure. This composite approach allows the battery to utilize abundant sodium while compensating for its lower voltage characteristics through material composition optimization, thereby maintaining high energy density.
Solution Approach 2:
The patent optimizes multiple parameters including cathode material composition, crystal structure, and electrochemical properties to maximize energy density despite sodium's inherent lower voltage. This involves precise control of material synthesis parameters and electrochemical operating conditions.
3Use of energy by moving object
If sodium-based secondary batteries use metallic sodium anode, then energy density is improved, but manufacturing difficulty increases due to reactivity of metallic sodium
Solution Approach 1:
The patent applies preliminary protective measures by coating the metallic sodium anode with stable materials before battery assembly and operation. This pre-protection prevents unwanted reactions during manufacturing and handling, making the production process safer and more manageable while preserving the high energy density benefits of metallic sodium.
Solution Approach 2:
The patent introduces intermediary protective layers between the metallic sodium anode and other battery components. These intermediary coatings act as barriers that reduce the reactivity of metallic sodium during manufacturing while allowing ionic transport during normal operation, thus enabling safe production without sacrificing energy density.
4Ease of manufacture
If sodium-based secondary batteries use lower operating voltage materials, then cost and material abundance are improved, but energy density deteriorates
Solution Approach 1:
The patent optimizes multiple parameters including cathode material composition, crystal structure, and electrochemical operating conditions to maximize energy density despite sodium's inherently lower voltage compared to lithium. This involves precise control of material synthesis parameters and electrochemical window selection.
Solution Approach 2:
The patent develops composite cathode materials that combine sodium-based compounds with other elements to create a synergistic structure that enhances voltage and energy density while maintaining cost-effectiveness and material abundance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves energy densities comparable to lithium-ion batteries, reduces costs, and enhances manufacturing efficiency, providing a sustainable and cost-effective alternative for high-energy and high-power rechargeable batteries.
Implementation Method 1
a non-aqueous electrolyte composition that fills the cell
Implementation Method 2
an in-situ formed sodium metal anode, utilizing a bare metal current collector and non-aqueous electrolytes
Data Source
AI summary
The present disclosure relates to a secondary sodium-based battery that can achieve energy densities comparable to state-of-the art lithium-ion batteries. The battery disclosed herein is designed to maximize energy density for a given sodium-based cathode and ease of manufacturing while minimizing cost. The battery can be constructed with any cathode that has sodium within its active material structure and a bare metal current collector to form the anode in-situ upon first charge cycle. The concepts of the present disclosure allow for ease of manufacturing as it reduces the required steps for anode processing as well as provide the energy density benefits of a sodium-metal anode without the requisite processing conditions.