Pre-Sodiated Copper-Zinc Cathode Material for Low-Gas Sodium-Ion Cells
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Solution Overview
Problem
Existing copper-based sodium ion battery materials suffer from low specific capacity, high gas production due to electrolyte decomposition, and high cost, limiting their widespread application.
Innovation Solution
A pre-sodium treated positive electrode material for copper-zinc-based sodium ion batteries is developed through a method involving sand grinding, spray drying, and sintering with sodium sources, reducing the oxidation of metal ions and enhancing sodium ion diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If copper-based positive electrode material is used, then cost is reduced, but specific capacity is low and gas production is high
Solution Approach 1:
The patent uses composite copper-zinc-based layered oxide materials combining Cu, Zn, Fe, Mn, and Ni elements in specific ratios. This composite approach achieves low cost (avoiding expensive Ni dominance) while improving specific capacity through synergistic effects of multiple metal ions with different redox potentials and structural stability.
Solution Approach 2:
The patent optimizes multiple parameters including metal ion ratios (Cu:Zn:Fe:Mn:Ni), oxidation states (Cu2+/Cu3+, Fe2+/Fe3+, Mn3+/Mn4+), particle size (5-15 μm), and sintering temperature (900-1000°C). These parameter changes enable the material to achieve high specific capacity while maintaining cost-effectiveness.
2Ease of manufacture
If copper-based positive electrode material is used, then cost is reduced, but gas production during cycling increases
Solution Approach 1:
The patent converts the harmful oxidizing nature of Cu2+ ions into a beneficial effect by controlling the Cu2+/Cu3+ ratio and using zinc-based layered structure to moderate the oxidation strength. The controlled oxidation enables electrochemical activity while reducing electrolyte decomposition and CO2 gas production.
Solution Approach 2:
The patent optimizes copper ion concentration (0.2-0.5 mol ratio), oxidation state distribution, and sintering temperature (900-1000°C) to control the oxidizing strength. These parameter changes reduce electrolyte oxidation while maintaining electrochemical activity, thereby reducing gas production during cycling.
3Quantity of substance
If nickel-iron-manganese series positive electrode material is used, then specific capacity is improved, but cost increases
Solution Approach 1:
The patent uses localized zinc substitution at specific lattice positions in the layered structure, creating regions with different functional properties. Zinc substitution at controlled levels (0.1-0.3 mol ratio) locally enhances structural stability and ion diffusion pathways without requiring expensive nickel throughout the entire structure.
Solution Approach 2:
The patent replaces expensive nickel with cheaper zinc-based compounds that provide similar structural stability and electrochemical performance. The zinc-rich composition (0.4-0.7 mol ratio) serves as a cost-effective alternative to nickel-iron-manganese systems while maintaining high specific capacity.
4Speed
If sand grinding and pre-sodium treatment are applied, then sodium ion diffusion is improved, but manufacturing complexity increases
Solution Approach 1:
The patent performs pre-sodium treatment during the sand grinding stage, introducing sodium ions into the precursor particles before final sintering. This preliminary action ensures uniform sodium distribution throughout the material structure, enhancing sodium ion diffusion kinetics without requiring complex post-processing steps.
Solution Approach 2:
The patent combines sand grinding, pre-sodium treatment, and precursor formation into a single integrated spray drying process. This merging of operations simplifies manufacturing by eliminating separate steps while achieving fine particle size (5-15 μm), uniform composition, and pre-loaded sodium content simultaneously.
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 method improves electrical performance by reducing gas production and stabilizing the electrochemical environment, while maintaining high specific capacity and lowering production costs.
Implementation Method 1
adding oxide of copper or oxide of zinc and mixed salt solution to a sand grinder for sand grinding for a certain period of time to obtain a mixed solution containing copper-zinc-based elements
Implementation Method 2
S2: spray drying for the mixed solution containing copper-zinc-based elements of S1 to obtain precursor powder of positive electrode material for copper-zinc-base sodium ion battery
Implementation Method 3
S3: mixing the precursor powder of S2 with a sodium source for sintering
Data Source
AI summary
A pre-sodium treated positive electrode material for copper-zinc-based sodium ion battery and method of preparing the same are provided. The method includes the steps of obtaining a mixed solution containing copper-zinc-based elements through wet pre-sodium first, then conducting spray drying of the mixed solution containing copper-zinc-based elements to obtain precursor powder of positive electrode material for copper-zinc-based sodium ion battery, and then mixing the precursor powder with a sodium source for sintering, coating and crushing to obtain positive electrode material for copper-zinc-based sodium ion battery. The pre-sodium treated positive electrode material for copper-zinc-based sodium ion battery thus prepared introduces weakly oxidizing zinc and nickel elements on the basis of the copper-based material, reducing the use of highly oxidizing copper and iron elements. After being prepared into a battery, the oxidation of metal ions in the electrochemical environment is reduced overall.