WO2023087067A1 - Improved battery - Google Patents

Improved battery Download PDF

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Publication number
WO2023087067A1
WO2023087067A1 PCT/AU2022/051382 AU2022051382W WO2023087067A1 WO 2023087067 A1 WO2023087067 A1 WO 2023087067A1 AU 2022051382 W AU2022051382 W AU 2022051382W WO 2023087067 A1 WO2023087067 A1 WO 2023087067A1
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Prior art keywords
carbon
battery
particles
aici3
mole
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PCT/AU2022/051382
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French (fr)
Inventor
Ashok Kumar Nanjundan
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Graphene Manufacturing Group Ltd
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Priority claimed from AU2021903741A external-priority patent/AU2021903741A0/en
Application filed by Graphene Manufacturing Group Ltd filed Critical Graphene Manufacturing Group Ltd
Publication of WO2023087067A1 publication Critical patent/WO2023087067A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/04—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of carbon-silicon compounds, carbon or silicon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y40/00—Manufacture or treatment of nanostructures
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00—Carbon; Compounds thereof
    • C01B32/15—Nano-sized carbon materials
    • C01B32/182—Graphene
    • C01B32/184—Preparation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/054—Accumulators with insertion or intercalation of metals other than lithium, e.g. with magnesium or aluminium
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/133—Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H01M4/1393—Processes of manufacture of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
    • H01M4/46—Alloys based on magnesium or aluminium
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
    • H01M4/583—Carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2204/00—Structure or properties of graphene
    • C01B2204/20—Graphene characterized by its properties
    • C01B2204/28—Solid content in solvents
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2204/00—Structure or properties of graphene
    • C01B2204/20—Graphene characterized by its properties
    • C01B2204/32—Size or surface area
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • H01B1/023—Alloys based on aluminium
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/06—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of other non-metallic substances
    • H01B1/08—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of other non-metallic substances oxides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
    • H01M4/46—Alloys based on magnesium or aluminium
    • H01M4/463—Aluminium based
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present invention generally relates to a battery.
  • a battery is a container consisting of one or more cells, in which chemical energy is converted into electricity and used as a source of power.
  • Aluminium ion batteries have potentially one of the highest energy densities of any battery technology up to 1050 Wh/kg however their nominal working voltage is from 1 .7 to 1 .9 volts.
  • a method for producing a battery part including: forming graphene nano-particles using carbon inclusive gas; combining the graphene nano-particles with one or more dispersing agents to form a combination; and mixing the combination with a battery part liquid.
  • the graphene nano-particles may be formed from carbon gas and one or more other carbon inclusive precursors including graphite, carbon black, activated carbon and hard and soft carbons; Graphene from Gas, Graphene from Graphite, Graphene Oxide from Graphite, Graphite, Modified carbon, Carbon Black.
  • the carbon source may be graphite, gas and liquids including carbon, and or biosolid feedstock.
  • the combination may include less than 0.01%, 0.05%, 0.10%, 0.5%, 1%, 2%, 3%, 10%, 50% or 80% by weight of graphene nano-particles.
  • the graphene nano-particles may be in the form of particles or platelets or flakes in the range of 2nm to tens of microns.
  • the graphene nano-particles are in the form of flakes added to said dispersing agents.
  • the mixing process may involve mixing with a high shear mixer, with shear rates ranging from a minimum of 1/10,000 per second, to disperse and distribute the graphene nano-particles.
  • the mixing times may range from 9 minutes to 72 hours, dependent upon varying dispersion and distribution combinations.
  • the battery part liquid may include any one or more of a metal and electrolyte mixture.
  • the dispersing agents may include HypermerTM manufactured by Croda and/or a hydrophilic non-ionic surfactant of the more general class of copolymers known as poloxamers (Brand names include: Pluronic F-127, Synperonic PE/F-127, Kolliphor P 407, Poloxalene).
  • the battery part may include an anode made from aluminium with a purity level of 97% to 99.99% and variable thickness gauge.
  • the battery part may include a cathode including a mixture of carbon, binder and solvent.
  • the binder may include a Carboxymethyl cellulose, Polyvinylidene fluoride or polyvinylidene difluoride, Polytetrafluoroethylene, Polystyrene, and/or National up 5-8% in water (h2O).
  • the solvent may include N-Methyl-2-pyrrolidone; Water; Dihydrolevoglucosenone; a Hydrocarbon solvent and/or Surfactant emulsion.
  • Material used to make the cathode may include carbon cloth, carbon paper molybdenum foil, and/or titanium foil.
  • the battery part may include an electrolyte.
  • the form of electrolyte may be in the form of 1 -ethyl-3-methylimidazolium chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1 .3 by mole); Urea-AICI3; Aluminum trifluoromethanesulfonatel -ethyl-3- methylimidazolium chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1.3 by mole); Urea- AICI3; Aluminum trifluoromethanesulfonate; (AI[TfO]3)/N-methylacetamide/urea; AICI3/acetamide; AICI3/N-methylurea; AICI3/1 ,3-dimethylurea; Bistrif limide, systematically known as bis(trifluoromethane) sulfonylimide (or 'imidate', see below) and colloquially as TFSI;
  • the battery may have an energy density of greater than 50 Wh/Kg up to 500 Wh/kg.
  • the battery may have volumetric energy density ranging from 20 Wh/L up to 1000 Wh/L.
  • the battery includes two cathodes and two anodes assembled in series to reach a nominal voltage of 3.4 to 3.8 volts.
  • a glass fiber separator is used to separate the anodes from cathodes to prevent short circuiting.
  • PDDF and PTFE Glass fibre;
  • Polytetrafluoroethylene or any synthetic fluoropolymer of tetrafluoroethylene; Cellulose membrane; and/or Poly acrylonitrile materials are used as the separators.
  • Table 1 is a table of production methodologies for the battery part or component.
  • an improved battery including battery parts.
  • the parts including graphene nano-particles formed from carbon containing gas (i.e. gas including carbon) and one or more other carbon containing precursors including graphite, carbon black, activated carbon and hard and soft carbons; Graphene from Gas, Graphene from Graphite, Graphene Oxide from Graphite, Graphite, Modified carbon, Carbon Black.
  • the carbon source may be graphite, gas and liquids containing carbon, and or biosolid feedstock.
  • the parts include a terminal, separator, electrolyte, and conductive intercell barrier.
  • the battery provides about double the voltage and an improvement in energy density over known batteries (e.g. Li-ion batteries with an energy density of 100-265 Wh/kg or 250-670 Wh/L).
  • known batteries e.g. Li-ion batteries with an energy density of 100-265 Wh/kg or 250-670 Wh/L.
  • graphene nano-particles are formed using carbon containing gases.
  • the graphene nano-particles are manufactured from carbon gas, thereby being added in significantly lesser quantity (typically up to 100 times) than graphene otherwise manufactured from graphite to obtain a comparable result.
  • the graphene nanoparticles are in the form of particles or platelets or flakes in the range of 2nm to few microns, typically 2 nm to 15 microns.
  • the graphene nano-particles are combined with one or more dispersing agents to form a combination.
  • the combination includes graphene dosage rates as low as 0.001% up to 85.0%, by weight.
  • the graphene nano-particles are in the form of flakes added to the dispersing agents.
  • the dispersing agents can include HypermerTM manufactured by Croda and/or a hydrophilic non-ionic surfactant of the more general class of copolymers known as poloxamers (Brand names include: Pluronic F-127, Synperonic PE/F-127, Kolliphor P 407, Poloxalene).
  • the combination is mixed with a battery part liquid including any one or more of N-Methyl-2-pyrrolidone, Water; Dihydrolevoglucosenone; a Hydrocarbon solvent; and Surfactant emulsion.
  • the mixing process involves mixing with a high shear mixer, with shear rates ranging from a minimum of 1/10,000 per second, to disperse and distribute the graphene nano-particles.
  • the mixing times may range from 9 minutes to 72 hours, dependent upon varying dispersion and distribution combinations.
  • the battery part liquid may include any one or more of a liquid conductor, molten metal and electrolyte, depending upon the part being formed.
  • Table 1 is a table of production methodologies for the battery part or component. Working principal concept examples led to doubling the voltage which can lead to an associated increase in cell capacity.
  • a battery can include multiple cathodes and anodes (i.e. the battery parts) in an assembled battery cell to linearly increase the voltage and thereby increase the cell capacity.
  • the battery part can include an anode made from aluminium with a purity level of 97% to 99.99% and variable thickness gauge.
  • the battery cathodes can be separate disc like structures of certain diameters (ranging from 8mm to 17mm in a 2032-coin cell).
  • the battery cathodes may resemble a single layer folded into multiple stacks of shapes (circles and squares) and separator membranes may be inserted into the cathodes and anode disc to form the complete electrode stack in the battery.
  • the battery part can include a cathode including a mixture of carbon, binder and solvent.
  • the binder may include a Carboxymethyl cellulose (CMC), polyacrylic acid (PAA) Polyvinylidene fluoride or polyvinylidene difluoride (PVDF), Polytetrafluoroethylene, Polystyrene, and/or a sulfonated tetrafluoroethylene based fluoropolymer-copolymer namely National up 5-8% in water (h2O).
  • the solvent may include N-Methyl-2-pyrrolidone; Water; Dihydrolevoglucosenone; a Hydrocarbon solvent and/or Surfactant emulsion.
  • Material used to make the cathode may include carbon cloth, carbon paper molybdenum foil, carbon coated aluminum foils, and/or titanium foil.
  • the battery part may include an electrolyte.
  • the form of electrolyte may be in the form of 1 -ethyl-3-methylimidazolium chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1 .3 by mole); Urea-AICI3; Aluminum trifluoromethanesulfonatel -ethyl-3- methylimidazolium chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1.3 by mole); Urea- AICI3; Aluminum trifluoromethanesulfonate; (AI[TfO]3)/N-methylacetamide/urea;
  • the source of the electrolyte chemistry can include Aluminium chloride powder; Recycled Aluminium powder; 1 -ethyl- 3-methylimidazolium chloride ionic liquid; and/or Urea
  • an aluminium ion battery includes two cathodes and two anodes assembled in series to reach a nominal voltage of 3.4 to 3.8 volts.
  • a glass fiber separator is used to separate the anodes from cathodes to prevent short circuiting.
  • PVDF and PTFE Glass fibre;
  • Polytetrafluoroethylene or any synthetic fluoropolymer of tetrafluoroethylene; Cellulose based membranes; nation based membranes and/or Poly acrylonitrile materials are used as the separators.

Abstract

The present invention relates to a method for producing a battery part. The method includes the step of forming graphene nano-particles using a carbon inclusive gas. The method involves combining the graphene nano-particles with one or more dispersing agents to form a combination. Further the method involves mixing the combination with a battery part liquid.

Description

IMPROVED BATTERY
TECHNICAL FIELD
[0001] The present invention generally relates to a battery.
BACKGROUND
[0002] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.
[0003] A battery is a container consisting of one or more cells, in which chemical energy is converted into electricity and used as a source of power.
[0004] Aluminium ion batteries have potentially one of the highest energy densities of any battery technology up to 1050 Wh/kg however their nominal working voltage is from 1 .7 to 1 .9 volts.
[0005] There is a need for an aluminium ion battery with an increased voltage up to 3.4 to 3.8 volts.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the present invention, there is provided a method for producing a battery part, the method including: forming graphene nano-particles using carbon inclusive gas; combining the graphene nano-particles with one or more dispersing agents to form a combination; and mixing the combination with a battery part liquid.
[0007] The graphene nano-particles may be formed from carbon gas and one or more other carbon inclusive precursors including graphite, carbon black, activated carbon and hard and soft carbons; Graphene from Gas, Graphene from Graphite, Graphene Oxide from Graphite, Graphite, Modified carbon, Carbon Black. The carbon source may be graphite, gas and liquids including carbon, and or biosolid feedstock.
[0008] Preferably, the combination may include less than 0.01%, 0.05%, 0.10%, 0.5%, 1%, 2%, 3%, 10%, 50% or 80% by weight of graphene nano-particles. The graphene nano-particles may be in the form of particles or platelets or flakes in the range of 2nm to tens of microns. Preferably, the graphene nano-particles are in the form of flakes added to said dispersing agents.
[0009] The mixing process may involve mixing with a high shear mixer, with shear rates ranging from a minimum of 1/10,000 per second, to disperse and distribute the graphene nano-particles. The mixing times may range from 9 minutes to 72 hours, dependent upon varying dispersion and distribution combinations.
[00010] The battery part liquid may include any one or more of a metal and electrolyte mixture. The dispersing agents may include HypermerTM manufactured by Croda and/or a hydrophilic non-ionic surfactant of the more general class of copolymers known as poloxamers (Brand names include: Pluronic F-127, Synperonic PE/F-127, Kolliphor P 407, Poloxalene).
[00011] The battery part may include an anode made from aluminium with a purity level of 97% to 99.99% and variable thickness gauge.
[00012] The battery part may include a cathode including a mixture of carbon, binder and solvent. The binder may include a Carboxymethyl cellulose, Polyvinylidene fluoride or polyvinylidene difluoride, Polytetrafluoroethylene, Polystyrene, and/or Nation up 5-8% in water (h2O). The solvent may include N-Methyl-2-pyrrolidone; Water; Dihydrolevoglucosenone; a Hydrocarbon solvent and/or Surfactant emulsion. Material used to make the cathode may include carbon cloth, carbon paper molybdenum foil, and/or titanium foil.
[00013] The battery part may include an electrolyte. The form of electrolyte may be in the form of 1 -ethyl-3-methylimidazolium chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1 .3 by mole); Urea-AICI3; Aluminum trifluoromethanesulfonatel -ethyl-3- methylimidazolium chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1.3 by mole); Urea- AICI3; Aluminum trifluoromethanesulfonate; (AI[TfO]3)/N-methylacetamide/urea; AICI3/acetamide; AICI3/N-methylurea; AICI3/1 ,3-dimethylurea; Bistrif limide, systematically known as bis(trifluoromethane) sulfonylimide (or 'imidate', see below) and colloquially as TFSI; and/or Trifluoromethanesulfonate. The source of the electrolyte chemistry can include Aluminium chloride powder; Recycled Aluminium powder; 1 -ethyl- 3-methylimidazolium chloride ionic liquid; and/or Urea.
[00014] The battery may have an energy density of greater than 50 Wh/Kg up to 500 Wh/kg. The battery may have volumetric energy density ranging from 20 Wh/L up to 1000 Wh/L.
[00015] Typically, some embodiments, the battery includes two cathodes and two anodes assembled in series to reach a nominal voltage of 3.4 to 3.8 volts. In some embodiments, a glass fiber separator is used to separate the anodes from cathodes to prevent short circuiting. In some embodiments PDDF and PTFE; Glass fibre;
Polytetrafluoroethylene or any synthetic fluoropolymer of tetrafluoroethylene; Cellulose membrane; and/or Poly acrylonitrile materials are used as the separators.
[00016] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.
BRIEF DESCRIPTION OF THE TABLE
[00017] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a table as follows:
[00018] Table 1 is a table of production methodologies for the battery part or component.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[00019] According to an embodiment of the present invention, there is provided an improved battery including battery parts. The parts including graphene nano-particles formed from carbon containing gas (i.e. gas including carbon) and one or more other carbon containing precursors including graphite, carbon black, activated carbon and hard and soft carbons; Graphene from Gas, Graphene from Graphite, Graphene Oxide from Graphite, Graphite, Modified carbon, Carbon Black. The carbon source may be graphite, gas and liquids containing carbon, and or biosolid feedstock. In particular, the parts include a terminal, separator, electrolyte, and conductive intercell barrier.
[00020] Advantageously, the battery provides about double the voltage and an improvement in energy density over known batteries (e.g. Li-ion batteries with an energy density of 100-265 Wh/kg or 250-670 Wh/L).
[00021] A method for producing the battery part is now described.
[00022] Initially, graphene nano-particles are formed using carbon containing gases. The graphene nano-particles are manufactured from carbon gas, thereby being added in significantly lesser quantity (typically up to 100 times) than graphene otherwise manufactured from graphite to obtain a comparable result. The graphene nanoparticles are in the form of particles or platelets or flakes in the range of 2nm to few microns, typically 2 nm to 15 microns.
[00023] Next, the graphene nano-particles are combined with one or more dispersing agents to form a combination. The combination includes graphene dosage rates as low as 0.001% up to 85.0%, by weight. Preferably, the graphene nano-particles are in the form of flakes added to the dispersing agents. The dispersing agents can include Hypermer™ manufactured by Croda and/or a hydrophilic non-ionic surfactant of the more general class of copolymers known as poloxamers (Brand names include: Pluronic F-127, Synperonic PE/F-127, Kolliphor P 407, Poloxalene).
[00024] Next, the combination is mixed with a battery part liquid including any one or more of N-Methyl-2-pyrrolidone, Water; Dihydrolevoglucosenone; a Hydrocarbon solvent; and Surfactant emulsion.
[00025] The mixing process involves mixing with a high shear mixer, with shear rates ranging from a minimum of 1/10,000 per second, to disperse and distribute the graphene nano-particles. The mixing times may range from 9 minutes to 72 hours, dependent upon varying dispersion and distribution combinations. [00026] The battery part liquid may include any one or more of a liquid conductor, molten metal and electrolyte, depending upon the part being formed.
[00027] Table 1 is a table of production methodologies for the battery part or component. Working principal concept examples led to doubling the voltage which can lead to an associated increase in cell capacity.
[00028] A battery can include multiple cathodes and anodes (i.e. the battery parts) in an assembled battery cell to linearly increase the voltage and thereby increase the cell capacity. The battery part can include an anode made from aluminium with a purity level of 97% to 99.99% and variable thickness gauge.
[00029] In some embodiments, the battery cathodes can be separate disc like structures of certain diameters (ranging from 8mm to 17mm in a 2032-coin cell).
[00030] In some embodiments, the battery cathodes may resemble a single layer folded into multiple stacks of shapes (circles and squares) and separator membranes may be inserted into the cathodes and anode disc to form the complete electrode stack in the battery.
[00031] The battery part can include a cathode including a mixture of carbon, binder and solvent. The binder may include a Carboxymethyl cellulose (CMC), polyacrylic acid (PAA) Polyvinylidene fluoride or polyvinylidene difluoride (PVDF), Polytetrafluoroethylene, Polystyrene, and/or a sulfonated tetrafluoroethylene based fluoropolymer-copolymer namely Nation up 5-8% in water (h2O). The solvent may include N-Methyl-2-pyrrolidone; Water; Dihydrolevoglucosenone; a Hydrocarbon solvent and/or Surfactant emulsion. Material used to make the cathode may include carbon cloth, carbon paper molybdenum foil, carbon coated aluminum foils, and/or titanium foil.
[00032] The battery part may include an electrolyte. The form of electrolyte may be in the form of 1 -ethyl-3-methylimidazolium chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1 .3 by mole); Urea-AICI3; Aluminum trifluoromethanesulfonatel -ethyl-3- methylimidazolium chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1.3 by mole); Urea- AICI3; Aluminum trifluoromethanesulfonate; (AI[TfO]3)/N-methylacetamide/urea;
AICI3/acetamide; AICI3/N-methylurea; AICI3/1 ,3-dimethylurea; Bistriflimide, systematically known as bis(trifluoromethane) sulfonylimide (or 'imidate', see below) and colloquially as TFSI; and/or Trifluoromethanesulfonate. The source of the electrolyte chemistry can include Aluminium chloride powder; Recycled Aluminium powder; 1 -ethyl- 3-methylimidazolium chloride ionic liquid; and/or Urea
[00033] The output voltage and therefore the capacity of the battery linearly increases with the number of cathodes and anodes in the assembled battery. Typically, some embodiments, an aluminium ion battery includes two cathodes and two anodes assembled in series to reach a nominal voltage of 3.4 to 3.8 volts. In some embodiments, a glass fiber separator is used to separate the anodes from cathodes to prevent short circuiting. In some embodiments PVDF and PTFE; Glass fibre;
Polytetrafluoroethylene or any synthetic fluoropolymer of tetrafluoroethylene; Cellulose based membranes; nation based membranes and/or Poly acrylonitrile materials are used as the separators.
[00034] A person skilled in the art will appreciate that many embodiments and variations can be made without departing from the ambit of the present invention.
[00035] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.
[00036] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

Claims

7 The claims defining the invention are as follows:
1 . A method for producing a battery part, the method including: forming graphene nano-particles using carbon inclusive gas; combining the graphene nano-particles with one or more dispersing agents to form a combination; and mixing the combination with a battery part liquid.
2. A method as claimed in claim 1 , wherein the graphene nano-particles are formed using one or more carbon inclusive precursors including any one or more of: graphite, carbon black, activated carbon and hard and soft carbons; Graphene from Gas, Graphene from Graphite, Graphene Oxide from Graphite, Graphite, Modified carbon, and Carbon Black.
3. A method for producing a battery part as claimed in claim 2, wherein the carbon source of the carbon inclusive precursors include any one or more of: graphite, gas and liquids including carbon, and biosolid feedstock.
4. A method as claimed in claim 1 , wherein the combination includes less than 0.01 %, 0.05%, 0.10%, 0.5%, 1 %, 2%, 3%, 10%, 50% or 80% by weight of graphene nano-particles.
5. A method as claimed in claim 1 , wherein the graphene nano-particles are in the form of particles or platelets or flakes in the range of 2nm to tens of microns.
6. A method as claimed in claim 1 , wherein the graphene nano-particles are in the form of flakes added to said dispersing agents.
7. A method as claimed in claim 1 , wherein the mixing involves mixing with a high shear mixer, with shear rates ranging from a minimum of 1/10,000 per second, to disperse and distribute the graphene nano-particles.
8. A method as claimed in claim 7, wherein mixing times range from 9 minutes to 72 hours, dependent upon varying dispersion and distribution combinations. 8
7. A method as claimed in claim 1 , wherein the battery part liquid includes any one or more of a metal and electrolyte mixture.
8. A method as claimed in claim 1 , wherein the dispersing agents include Hypermer™ manufactured by Croda and/or a hydrophilic non-ionic surfactant of the more general class of copolymers known as poloxamers.
9. A method as claimed in claim 1 , wherein the battery part includes an anode made from aluminium with a purity level of 97% to 99.99% and variable thickness gauge.
10. A method as claimed in claim 1 , wherein the battery part includes a cathode, preferably including a mixture of carbon, binder and solvent.
11. A method as claimed in claim 10, wherein the binder includes a Carboxymethyl cellulose (CMC), polyacrylic acid (PAA) Polyvinylidene fluoride or polyvinylidene difluoride (PVDF), Polytetrafluoroethylene, Polystyrene, and/or a sulfonated tetrafluoroethylene based fluoropolymer-copolymer namely Nation up 5-8% in water (h2O).
12. A method as claimed in claim 10, wherein the solvent includes N-Methyl-2- pyrrolidone; Water; Dihydrolevoglucosenone; a Hydrocarbon solvent and/or Surfactant emulsion.
13. A method as claimed in claim 10, wherein material used to make the cathode includes carbon cloth, carbon paper molybdenum foil, carbon coated aluminum foils, and/or titanium foil.
14. A method as claimed in claim 10, wherein the battery cathode is a disc like structure and/or resembles a single layer which is folded.
15. A method as claimed in claim 1 , wherein the battery part includes an electrolyte
16. A method as claimed in claim 15, wherein the electrolyte is in the form of 1 -ethyl- 3-methylimidazolium chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1 .3 by mole; 1 :1 .7 by mole; and 1 :2 by mole); Urea-AICI3 (1 :1 .3 by mole and 1 :1 .7 by mole; and 1 :2 by mole); Urea-AICI3; Aluminum trifluoromethanesulfonate1 -ethyl-3-methylimidazolium 9 chloride-aluminum chloride; ([EMIm]CI-AICI3, 1 :1.3 by mole); Urea-AICI3; Aluminum trifluoromethanesulfonate; (AI[TfO]3)/N-methylacetamide/urea; AICI3/acetamide; AICI3/N-methylurea; AICI3/1 ,3-dimethylurea; Bistriflimide, systematically known as bis(trifluoromethane) sulfonylimide (or 'imidate') and colloquially as TFSI; and/or T rifluoromethanesulfonate.
17. A method as claimed in claim 15, wherein the source of the electrolyte chemistry includes Aluminium chloride powder; Recycled Aluminium powder; 1 -ethyl-3- methylimidazolium chloride ionic liquid; and/or Urea.
18. A method as claimed in claim 1 , wherein a battery including the battery part has an energy density of greater than 50 Wh/Kg up to 500 Wh/kg and/or a volumetric energy density ranging from 20 Wh/L up to 1000 Wh/L.
19. A method as claimed in claim 18, wherein the battery includes two cathodes and two anodes assembled in series to reach a nominal voltage of 3.4 to 3.8 volts.
20. A method as claimed in claim 18, wherein a separator is used to separate the anodes from cathodes to prevent short circuiting.
21 . A method as claimed in claim 20, wherein the separator includes PVDF and PTFE; Glass fibre; Polytetrafluoroethylene or any synthetic fluoropolymer of tetrafluoroethylene; Cellulose based membranes; nation based membranes and/or Poly acrylonitrile materials.
22. A battery including multiple cathodes, separators and anodes in an assembled battery cell to linearly increase the voltage and also increase the cell capacity.
PCT/AU2022/051382 2021-11-19 2022-11-18 Improved battery WO2023087067A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8795899B2 (en) * 2010-08-19 2014-08-05 Nanotek Instruments, Inc. Lithium super-battery with a functionalized nano graphene cathode
US20160318765A1 (en) * 2013-03-11 2016-11-03 Samsung Electronics Co., Ltd. Method for preparing graphene
KR20170019791A (en) * 2015-08-12 2017-02-22 주식회사 엘지화학 Electrode assembly
US20210226225A1 (en) * 2020-01-10 2021-07-22 Lyten, Inc. Metal-air battery including electrolyte beads

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8795899B2 (en) * 2010-08-19 2014-08-05 Nanotek Instruments, Inc. Lithium super-battery with a functionalized nano graphene cathode
US20160318765A1 (en) * 2013-03-11 2016-11-03 Samsung Electronics Co., Ltd. Method for preparing graphene
KR20170019791A (en) * 2015-08-12 2017-02-22 주식회사 엘지화학 Electrode assembly
US20210226225A1 (en) * 2020-01-10 2021-07-22 Lyten, Inc. Metal-air battery including electrolyte beads

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