published_or_final_version / Environmental Management / Master / Master of Science in Environmental Management

Development of alternative cathodes that have high capacity and long cycle life at an affordable cost is critical for next generation rechargeable batteries to meet the ever-increasing requirements of global energy storage market. Lithium-sulfur batteries, employing sulfur cathodes, are increasingly being investigated due to their high theoretical capacity, low cost, and environmental friendliness. However, the practicality of lithium-sulfur technology is hindered by technical obstacles, such as short shelf and cycle life, arising from the shuttling of polysulfide intermediates between the cathode and the anode as well as the poor electronic conductivity of sulfur and the discharge product Li2S. This dissertation focuses on overcoming some of these problems. The sulfur cathode involves an electrochemical conversion reaction compared to the conventional insertion-reaction cathodes. Therefore, modifications in cell-component configurations/structures are needed to realize the full potential of lithium-sulfur cells. This dissertation explores various custom and functionalized cell components that can be adapted with pure sulfur cathodes, e.g., porous current collectors in Chapter 3, interlayers in Chapter 4, sandwiched electrodes in Chapter 5, and surface-coated separators in Chapter 6. Each chapter introduces the new concept and design, followed by necessary modifications and development. The porous current collectors embedded with pure sulfur cathodes are able to contain the active material in their porous space and ensure close contact between the insulating active material and the conductive matrix. Hence, a stable and reversible electrochemical-conversion reaction is facilitated. In addition, the use of highly porous substrates allows the resulting cell to accommodate high sulfur loading. The interlayers inserted between the pure sulfur cathode and the separator effectively intercept the diffusing polysulfides, suppress polysulfide migration, localize the active material within the cathode region, and boost cell cycle stability. The combination of porous current collectors and interlayers offers sandwiched electrode structure for the lithium/dissolved polysulfide cells. By way of integrating the advantages from the porous current collector and the interlayer, the sandwiched electrodes stabilize the dissolved polysulfide catholyte within the cathode region, resulting in a high discharge capacity, long-term cycle stability, and high sulfur loading. The novel surface-coated separators have a polysulfide trap or filter coated onto one side of a commercial polymeric separator. The functional coatings possess physical and/or chemical polysulfide-trapping capabilities to intercept, absorb, and trap the dissolved polysulfides during cell discharge. The functional coatings also have high electrical conductivity and porous channels to facilitate electron, lithium-ion, and electrolyte mobility for reactivating the trapped active material. As a result, effective reutilization of the trapped active material leads to improved long-term cycle stability. The investigation of the key electrochemical and engineering parameters of these novel cell components has allowed us to make progress on (i) understanding the materials chemistry of the applied functionalized cell components and (ii) the electrochemical performance of the resulting lithium-sulfur batteries. / text

This thesis explores mechanical behavior of microelectronic devices and lithium-ion batteries. We first examine electromigration-induced void formation in solder bumps by constructing a theory that couples electromigration and creep. The theory can predict the critical current density below which voids do not form. Due to the effects of creep, this quantity is found to be independent of the solder size and decrease exponentially with increasing temperature, different from existing theories. / Engineering and Applied Sciences

Lithium ion batteries have become one of the most popular types of battery in consumer electronics as well as aerospace and automotive applications. The efficient use of Li-ion batteries in automotive applications requires well designed battery management systems. Low order Li-ion battery models that are fast and accurate are key to well- designed BMS. The control oriented low order physics based model developed previously cannot predict the temperature and predicts inaccurate voltage dynamics. This thesis focuses on two things: (1) the development of a thermal component to the isothermal model and (2) the development of a hybrid neural net and physics based battery model that corrects the output of the physics based model. A simple first law based thermal component to predict the temperature model is implemented. The thermal model offers a reasonable approximation of the temperature dynamics of the battery discharge over a wide operating range, for both a well-ventilated battery as well as an insulated battery. The model gives an accurate prediction of temperature at higher SOC, but the accuracy drops sharply at lower SOCs. This possibly is due to a local heat generation term that dominates heat generation at lower SOCs. A neural net based modeling approach is used to compensate for the lack of knowledge of material parameters of the battery cell in the existing physics based model. This model implements a neural net that corrects the voltage output of the model and adds a temperature prediction sub-network. Given the knowledge of the physics of the battery, sparse neural nets are used. Multiple types of standalone neural nets as well as hybrid neural net and physics based battery models are developed and tested to determine the appropriate configuration for optimal performance. The prediction of the neural nets in ventilated, insulated and stressed conditions was compared to the actual outputs of the batteries. The modeling approach presented here is able to accurately predict voltage output of the battery for multiple current profiles. The temperature prediction of the neural nets in the case of the ventilated batteries was harder to predict since the environment of the battery was not controlled. The temperature predictions in the insulated cases were quite accurate. The neural nets are trained, tested and validated using test data from a 4.4Ah Boston Power lithium ion battery cell. / text

This dissertation is composed of seven chapters, detailing advances within the area of sulfur polymer chemistry and processing, and highlights the relevance of the work to the fields of polymer science, energy storage, and optics that are enabled through the development of novel high sulfur-content copolymers as discussed in the following chapters. The first chapter is a review summarizing both the historical forays into utilization of elemental sulfur in high sulfur-content materials and the current research on the incorporation of sulfur into novel copolymers and composites for high value added applications such as energy production/storage, polymeric optical components, and dynamic/self-healing materials. Although recent efforts by the materials and polymer chemistry communities have afforded innovative sulfur containing materials, many studies fail to take advantage of the low cost and incredible abundance of sulfur by incorporating only minimal quantities into the end products. A fundamental challenge in the preparation of sulfur-containing polymers is simultaneous incorporation of high sulfur-content through facile chemical methods, to truly use the element as a novel feedstock in copolymerizations. Contributing to the challenge are the intrinsic limitations of sulfur (i.e., low miscibility with organic solvents, high crystallinity, and poor processability). The emphasis in chapter 1 is the critical development of utilizing sulfur as both a reagent and solvent in a bulk reaction, termed inverse vulcanization. Through this methodology we can directly prepare materials which retain the advantageous properties of elemental sulfur (i.e., high electrochemical capacity, high refractive index, and liable bond character), obviate the processing challenges, and enable precise control over composition and properties in a facile manner. The second chapter focuses on advancement in colloid synthesis, specifically an example mediated by in-situ reduction of organometallic precursors (ClAu^IPPh₃) by elemental sulfur at high temperatures. In chapter 2, elemental sulfur is employed both as a reactant and novel solvent, generating composite composed of well-defined gold nanoparticles (Au NPs) fully dispersed in a sulfur matrix. While the synthesis of Au NPs in molten sulfur was a novel development the challenge of analyzing the particles directly within the sulfur composite matrix by microscopy techniques required improvement of the composites mechanical properties. To overcome this issue, a one-pot reaction in which the Au NPs were initially synthesized, was vulcanized through an ambient atmosphere-tolerant bulk copolymerization by the addition of a difunctional comonomer (divinylbenzene). The improved composite integrity enabled microtoming and transmission electron microscopy analysis of the particles within the crosslinked reaction matrix. Due to the facile capabilities of directly dissolving the comonomers within the molten sulfur the inverse vulcanization methodology provides a simple route to prepare stable, high sulfur-content copolymers in a single one-pot reaction. The third chapter expands upon the methodology for direct dissolution of difunctional comonomers into molten elemental sulfur to afford chemically stable copolymer. A major challenge associated with the high temperature (i.e., 185 °C) bulk copolymerization reactions between sulfur and vinyl comonomers (i.e., divinylbenzene, DVB) is the high volatility of the organic monomers at elevated temperatures (BP of DVB = 195 °C). To obviate this problem required a novel monomer with an increased boiling point for successful scaling of the inverse vulcanization methodology. The work presented in chapter 3 details the employment of 1,3-diisopropenylbenzene (DIB, BP = 231 °C) to enable larger scale bulk inverse vulcanization reactions, allowing facile control over thermomechanical properties by simple variation in copolymer composition (50–90-wt% S₈, 10–50-wt% DIB). Poly(Sulfur-random-1,3-diisopropenylbenzene) ((poly(S-r-DIB)) copolymers prepared via the inverse vulcanization methodology possess substantially improved processing capabilities compared with elemental sulfur. A facile demonstration of improved processability is the generation of free-standing micropatterned structures using a high sulfur content liquid pre-polymer resin that can be poured into a mold and cured into the desired final form. The highest weight percentage copolymer (i.e., 90-wt% S₈) was also demonstrated to improve cycle lifetimes and capacity retention (823 mAh•g⁻¹ at 100 cycles) of a Lithium-Sulfur (Li-S) cell when the copolymer was utilized as the active material instead of elemental sulfur. Chapter four focuses on the optimization of Li-S cell performance as a function of copolymer composition and provides a more thorough understanding of the means by which copolymer active material improves battery performance. A substantial challenge associated with Li-S cells is the fast capacity fade and short cycle lifetimes that result from loss of the active material (i.e., sulfur) during normal cycling processes. The field has generally addressed these issues by encapsulation of the sulfur in a protective shell (e.g., polymeric, carbonaceous, or metal oxide in nature) in an attempt to sequester the active material. However, encapsulation of sulfur is non-trivial and leads to low loadings of sulfur, resulting in a low energy density within the final cell. To address the challenges associated with maintaining high capacity and long cycle lifetimes while employing an active material which is low cost, generated in a facile manner, and has a high sulfur content required a novel approach. In the work presented in chapter 4 we prepared high sulfur content copolymers via the inverse vulcanization methodology, which meet all the requirements necessary of an active material, and investigated the performance of Li-S batteries as a function of the copolymer composition. A survey of several poly(S-r-DIB) copolymer compositions were prepared with DIB compositions ranging from 1-50-wt% DIB (i.e., 50-99 wt% sulfur) and screened to determine optimal compositions for optimal Li-S battery performance. From this analysis it was determined that copolymers with 10-wt% DIB (90-wt% S₈) were optimal for producing Li-S batteries with high capacity and long cycle lifetimes. 10-wt% DIB copolymers batteries ultimately achieved long cyclic lifetimes and maintained high capacity (>600 mAh/g at 500 cycles). Chapter five details the optimization of conditions necessary to generate large scale (>100 g) inversely vulcanized sulfur copolymers and their application towards Li-S batteries. As previously stated a significant challenge in the Li-S battery field is the production of a Li-S active material with improved performance that is low cost, synthesized in a facile manner, and possesses high sulfur content. To date poly(S-r-DIB) copolymers prepared via the inverse vulcanization methodology afford some of the longest cycle lifetimes and highest capacity retention for polymeric active materials. However, initial inverse vulcanization reactions investigated for preparing active materials were performed on 10 gram scales. The goal of the work presented in chapter 5 was to prepare materials on a scale applicable to fabrication of several prismatic Li-S cells, each of which requires several grams of active material. However, scaling up of the reaction to a kilogram and utilizing the traditional inverse vulcanization conditions (i.e., 185 °C) results in catastrophic degradation as a consequence of the Trommsdorf effect. To address this challenge required decreasing the radical concentration within the bulk copolymerization, which necessitated performing the kilogram scale inverse vulcanization reactions at lower temperatures (i.e., 130 °C) over a longer reaction period. Decreasing the temperature generates materials that are nearly identical in thermomechanical properties to smaller scale samples and the battery performance is likewise comparable (>600 mAh/g at 500 cycles). The key advantage of performing the inverse vulcanization reaction at lower temperatures is that additional monomers, with lower boiling points or degradation issues, can be utilized and the increased gelation time, enables facile incorporation of additives (e.g., carbon black or nanoparticles) into the reaction. Chapter six focuses on the development of poly(S-r-DIB) copolymers as novel mid-infrared (mid-IR) transmitting materials and the analysis of the optical properties as a function of copolymer composition. A challenge in the optical science community is the limited number of materials applicable to the development of innovative optical components capable of functioning in the mid and far-IR regions. Semi-conductor and chalcogenide glasses have been widely applied as device components in infrared optics due to their high refractive indices (n ~2.0–4.0) and high transparency in the infrared region (1–10 μm). However, such materials are also expensive, difficult to fabricate, and toxic in comparison to organic polymers. On the other hand organic polymers are easily processed, low cost, and generated from easily accessible raw materials. Unfortunately, polymeric materials generally have low refractive indices (n<1.65) and are prepared from monomers with functional groups that are highly absorbing at mid-IR and longer wavelengths. Chapter 6 details the realization through the inverse vulcanization methodology of the first example of a material that is high refractive index and low mid-IR absorption, but also low cost and easily processable. Critical to achieving a polymeric material which was appropriate for mid-IR applications was the high sulfur content and the absence of functional groups, both of which are afforded by the facile copolymerization process. By simply controlling copolymer composition the optical properties of the material were tailorable; allowing adjustment of the refractive index from ~1.75 (50-wt% DIB) to ~1.875 (20-wt% DIB). Finally, through facile techniques, high quality copolymers lenses were prepared and we demonstrated the high optical transparency over several regions of the optical spectrum, from the visible (400–700 nm) all the way to the mid-IR (3–5μm). Poly(S-r-DIB) copolymers demonstrated high transparency to mid-IR light, but still maintain the processing capabilities of an organic polymer, the first example of such a material to possess both qualities. Ultimately the inverse vulcanization methodology offers a novel route to low cost, high refractive index, IR transparent materials, opening up unique opportunities for polymeric optical components within the optical sciences field. The seventh chapter discusses utilization of the inverse vulcanization methodology as a means to prepare and control the dynamic behavior of sulfur copolymers for potential applications towards self-healing materials. The incorporation of dynamic covalent bonds into conventional polymer architectures, either directly within the backbone or as side-chain groups, offers the stability of covalent bonds but with the ability of stimuli-responsive behavior to afford a change in chemical makeup or morphology. Traditionally the installation of such functionality requires the use of disparate, orthogonally polymerizable functional groups (i.e., vinyl) and discrete design of the comonomers utilized to generate a responsive copolymer. Therefore, a challenge in developing novel dynamic copolymers is the ability to install stimuli-responsive functionality directly as a result of the copolymerization without the need for rigorous synthetic monomer design and complex copolymerization techniques. In chapter 7 we discuss the analysis of poly(S-r-DIB) copolymers with rheological techniques to assess the composition dependent dynamic behavior. Aided by the bulk nature of copolymerization, the feed ratio of S₈ and DIB directly dictates copolymer microstructure; thus the sulfur rank between the organic groups (i.e., DIB) was tailorable from a single sulfur (thioether) to multiple sulfurs (pentasulfide). Control over sulfur content and number of S–S enables control over the dynamic behavior, as monitored via in-situ rheological techniques. The highest sulfur-content copolymers (80-wt% S₈, 20-wt% DIB) showed the fastest response when under shear stress due to the large number of S–S bonds. On the other hand when no dynamic bonds were present in the copolymer (i.e.; 35-wt% S₈, 65-wt% DIB) there is no dynamic behavior and full recovery of the pristine mechanical properties was not observed. The facile synthesis and simple control over copolymer microstructure affords the inverse vulcanization methodology an advantage over other dynamic materials, and provides potential secondary qualities (i.e., high refractive index) built directly into the structure.

This study was undertaken to understand the effect of applied pressure on the performance of the lithium sulfur cathode. Compressible carbon based cathodes and novel nickel based cathodes were fabricated. For each cathode, pore volume and void volume were quantified and void fraction was calculated, compression under 0 to 2MPa was measured, and lithium-sulfur cells were assembled and cycled at pressures between 0 and 1MPa. The cathodes studied had void fractions in the range of 0.45 to 0.90. Specific discharge capacities between 200 and 1100 mAh/g under 1MPa were observed in carbon-based cathodes. Nickel-based cathodes showed increased specific discharge capacity of up to 1300 mAh/g, with no degradation of performance under pressure. The high correlation of specific discharge capacity and void fraction, in conjunction with previous work, strongly suggest that the performance of lithium-sulfur cathodes is highly dependent on properties that influence ionic mass transport in the cathode.

The power requirement for the soldier's equipment is largely supplied by batteries. Situational awareness is critical for a soldier to perform his tasks. Therefore the radio used by the soldier is a key element in situational awareness and also consumes the most power. The South African National Defence Force (SANDF) uses the A43 tactical radio specifically designed for them. The radios are regarded as old technology but will be in use for about another five years. The radios still use non-rechargeable alkaline batteries which do not last very long and are not cost effective. The purpose of this study is to research the new generation secondary batteries as a possible replacement for the alkaline battery packs. The new generation batteries investigated in this study are the latest rechargeable batteries, also called secondary batteries. They include nickel cadmium, nickel metal hydride, lithium ion, rechargeable alkaline manganese and zinc air. The main features of rechargeable cells are covered and the cell characteristics are defined to allow the technology to be matched to the user requirement. Li-ion technology was found to be the best choice. This research also showed that international trends in battery usage are towards Li-ion. A new Li-ion battery was designed based on commercial cells. Tests showed that commercial Li-ion cells can be used in the radio and that they outperform the current battery by far. The study also examined the design of a New Generation Battery System consisting of an intelligent battery, a charger which uses a Systems Management Bus and a battery 'state of health" analyser to assist the user to maintain the batteries. Tests were done to demonstrate that the battery can withstand typical military environmental conditions. Expected military missions for a battery system were defined and used to compare the cost between the existing batteries and the new batteries system. Important usage factors which will influence the client when using a New Generation Battery System were addressed. To summarise, this study showed that by using a New Generation Battery System, the SANDF could relieve the operational cost of the A43 radio while saving on weight and enabling the soldier to carry out longer missions. / Thesis (M.Ing. (Electronical Engineering))--North-West University, Potchefstroom Campus, 2008.

The layered transition metal oxide composition series of Li1+xV1-xO2 was synthesized using the solid state synthesis technique. X-ray diffraction was used to determine the dependence of structure on composition and clearly indicated a structural anomaly at x = 0 caused by the unusual magnetic ordering on the triangular lattice of the V3+ layer. To prevent magnetic frustration V3+ cations undergo orbital ordering and subsequent periodic displacent to form “trimers”. The periodicity of this phenomena results in a superlattice structure that can be observed as a faint peak in XRD spectra. The relationship between composition, superlattice peak intensity and lattice parameters was clearly documented for the first time. Li/Li1+xV1-xO2 cells were made and tested. Recent literature has shown that the transformation to 1T Li2VO2 upon lithiation is dependant on a nonzero x (ideally x = 0.07 for maximum capacity) to make a small number of tetrahedrally coordinated Li sites accessible. These sites then act as a trigger for shearing into the 1T phase. The cells described within this work intercalated significant amounts of lithium at a higher potential than the to 1T transition, possibly signifying occupation of a large number of the tetrahedral sites. LiVO2 is known to undergo delithiation even in ambient conditons and this can lead to cationic disorder. Cationic disorder is an inhibitor of anion sheet shearing and this suggests that sample handling could be a cause of the observed electrochemical behaviour. The effects of air and water exposure were investigated.

The improvement of volumetric energy density remains a key area of research to opti-mize Li-ion batteries for applications such as extending the range of electric vehicles. There is still improvement to be made in the energy density in the positive elec-trode materials. The current thesis deals with determining the phase diagrams of the Li-Mn-Ni-O and Li-Co-Mn-O systems in order to better understand the structures and the electrochemistry of these materials. The phase diagrams were made through careful analysis of hundreds of X-ray di raction patterns taken of milligram-scale combinatorial samples. A number of bulk samples were also investigated. The Li-Mn-Ni-O system is of particular interest as avoiding cobalt lowers the cost of the material. However, this system is very complex: there are two large solid-solution regions separated by three two-phase regions as well as two three-phase regions. Comparing quenched and slow cooled samples shows that the system trans-form dramatically when cooled at rates typically used to make commercial materials. The consequences of these results are that much of the system must be avoided in order to guarantee that the materials remain single phase during cooling. This work should therefore impact signi cantly researchers working on composite electrodes. Two new structures were found. The first was Li-Ni-Mn oxide rocksalt structures with vacancies and ordering of manganese which were previously mistakenly identi ed as LixNi2xO2. The other new structure was a layered oxide with metal site vacancies allowing manganese to order on two superlattices. The electrochemistry of both these materials is presented here. Finally, the region where layered-layered composites form during cooling has been determined. These materials were long looked for along the composition line from Li2MnO3 to LiNi0.5Mn0.5O2 and the most significant consequence of the actual locations of the end-members is that one of the structures contains a high concentration of nickel on the lithium layer. Layered-layered nano-composites formed in this system are therefore not ideal positive electrode materials and it will be demonstrated that single-phase layered materials lead to better electrochemistry.

The potential use of 3D aluminium nanorod structures as current collectors and negative electrodes for 3D Li-ion micro-batteries was studied based on the use of relatively simple and cost-effective electrochemical and sol-gel deposition techniques. Aluminium rod structures were synthesised by galvanostatic electrodeposition using commercial porous membranes as templates. It was shown that the use of a short (i.e., 50 ms long) potential pulse (i.e., -0.9 V vs. Al3+/Al) applied prior to a pulsed current electrochemical deposition gave rise to homogeneous deposits with more even rod heights.  Electrophoretic and sol-gel deposition of TiO2 on the same substrates were also studied. The use of the sol-gel technique successfully resulted in a thin coating of amorphous TiO2 on the Al nanorod current collector, but with relatively small discharge capacities due to the amorphous character of the deposits. Electrophoretic deposition was, however, successful only on 2D substrates. Anodisation of titanium was used to prepare 3D TiO2 nanotube electrodes, with a nanotube length of 9 um and wall thickness of 50 nm. The electrodes displayed high and stable discharge capacities of 460 µAh/cm2 at a 0.1 C rate upon prolonged cycling with good rate capability. The 3D aluminium nanorod structures were tested as negative electrodes for Li-ion cells and the observed capacity fading was assigned to trapping of LiAl alloy inside the aluminium electrode caused by the diffusion of lithium into the electrode, rather than to pulverisation of the aluminium rods. The capacity fading effect could, however, be eliminated by decreasing the oxidation potential limit from 3.0 to 1.0 V vs. Li+/Li. A model for the alloying and dealloying of lithium with aluminium was also proposed. Finally, a proof-of-concept for a full 3D Li-ion micro-battery with electrodes of different geometries was demonstrated. The cell comprised a positive electrode, based on LiFePO4 deposited on a carbon foam current collector, with an area gain factor an order of magnitude larger than that for the Al nanorod negative electrode. This concept facilitates the balancing of 3D Li-ion cells as the positive electrode materials generally have significant lower specific energy densities than the negative electrodes.