The aim of this master thesis was to establish if sodium is trapped in aluminium current collectors, which in turn could affect the capacity fade in sodium-ion battery systems. In the case of lithium-ion batteries, previous studies have shown that a trapping mechanism, where lithium diffuses through the active material and current collectors, can explain the capacity fade observed for several systems. However, no such reports have been published in the sodium case, motivating this pioneering investigation. Contact samples of sodium and aluminium current collector material confirmed the uptake of sodium as shown by ICP-AES analyses. The uptake of sodium in the aluminium was equivalent to a charge of 0.4 µAh after 70 days of contact at 55°C. The main characterisation method was galvanostatic plating and stripping of sodium on aluminium in a pouch-cell configuration. When using a bare aluminium working electrode with a metallic sodium counter electrode in a 1 M NaPF6/diglyme electrolyte, the galvanostatic cycling showed coulombic efficiency instabilities. It was concluded that a more stable, high efficient plating-stripping would be needed to quantify the effects of sodium trapping with the employed electrochemical methods. Coulombic efficiency values that exceeded 100 % were attributed to the oxidation of disconnected (detached) sodium from previous plating cycles. On consecutive cycles some of the disconnected sodium got reconnected, resulting in coulombic efficiency values well over 100 %.

<p>Fuel cells are promising candidates for converting chemical energy into electrical energy. The Molten Carbonate Fuel Cell (MCFC) is a high temperature fuel cell that produces electrical energy from a variety of fuels containing hydrogen, hydrocarbons and carbon monoxide. Since the waste heat has a high temperature it can also be used leading to a high overall efficiency.</p><p>Material degradation and the cost of the components are the problems for the commercialisation of MCFC. Although there are companies around the world starting to commercialise MCFC some further cost reduction is needed before MCFC can be fully introduced at the market.</p><p>In this work, alternative materials for three different components of MCFC have been investigated. The alternative materials should have a lower cost compared to the state-of-the-art materials but also meet the life-time goal of MCFC, which is around 5 years. The nickel dissolution of the cathode is a problem and a cathode with lower solubility is needed. The dissolution of nickel for three alternative cathode materials was investigated, where one of the materials had a lower solubility than the state-of-the-art nickel oxide. This material was also tested in a cell and the electrochemical performance was found to be comparable with nickel oxide and is an interesting candidate.</p><p>An inexpensive anode current collector material is also desired. For the anode current collector, the contact resistance should be low and it should have good corrosion properties. The two alternative materials tested had low contact resistance, but some chromium enrichment was seen at the grain boundaries. This can lead to a decreased mechanical stability of the material. In the wet-seal area, the stainless steel used as bipolar/separator plate should be coated. An alternative process to coat the stainless steel, that is less expensive, was evaluated. This process can be a suitable process, but today, when the coating process is done manually there seems to be a problem with the adherence.</p><p>This work has been a part of the IRMATECH project, which was financed by the European Commission, where the partners have been universities, research institutes and companies around Europe.</p>

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

Fuel cells are promising candidates for converting chemical energy into electrical energy. The Molten Carbonate Fuel Cell (MCFC) is a high temperature fuel cell that produces electrical energy from a variety of fuels containing hydrogen, hydrocarbons and carbon monoxide. Since the waste heat has a high temperature it can also be used leading to a high overall efficiency. Material degradation and the cost of the components are the problems for the commercialisation of MCFC. Although there are companies around the world starting to commercialise MCFC some further cost reduction is needed before MCFC can be fully introduced at the market. In this work, alternative materials for three different components of MCFC have been investigated. The alternative materials should have a lower cost compared to the state-of-the-art materials but also meet the life-time goal of MCFC, which is around 5 years. The nickel dissolution of the cathode is a problem and a cathode with lower solubility is needed. The dissolution of nickel for three alternative cathode materials was investigated, where one of the materials had a lower solubility than the state-of-the-art nickel oxide. This material was also tested in a cell and the electrochemical performance was found to be comparable with nickel oxide and is an interesting candidate. An inexpensive anode current collector material is also desired. For the anode current collector, the contact resistance should be low and it should have good corrosion properties. The two alternative materials tested had low contact resistance, but some chromium enrichment was seen at the grain boundaries. This can lead to a decreased mechanical stability of the material. In the wet-seal area, the stainless steel used as bipolar/separator plate should be coated. An alternative process to coat the stainless steel, that is less expensive, was evaluated. This process can be a suitable process, but today, when the coating process is done manually there seems to be a problem with the adherence. This work has been a part of the IRMATECH project, which was financed by the European Commission, where the partners have been universities, research institutes and companies around Europe. / QC 20101123

The increasing energy demand requires a transition from fossil fuels to renewable resources. Lithium-ion batteries (LIBs) offer a promising solution as efficient energy storage devices. However, the aluminum current collector (CC) in LIBs is susceptible to anodic dissolution above 3 V vs. Li+/Li in commercial carbonate liquid electrolytes, compromising the battery performance. In this study, various approaches were explored to mitigate anodic dissolution in LiFSI EC:DEC at high voltages of the aluminum CC in LIBs, employing cyclic voltammetry (CV) and scanning electron microscopy (SEM). It was found that boiling the Al foil in water in an air atmosphere to increase the thickness of the surface Al2O3 layer improved the anodic stability and offered enhanced protection against proton attack (due to the oxidation of the carbonate solvent at high voltage). However, increasing the LiFSI electrolyte concentration to 2 M did not increase the anodic stability due to the absence of a passivating AlF3 layer. Notably, in 4 M LiFSI, impurity-induced high F- concentration facilitated the formation of a passivating AlF3 layer, resulting in improved anodic stability. Moreover, specific volume ratios of LiFSI EC:DEC and 1 M LiPF6 EC:DEC (1:1) (LP40) yielded the F- concentration necessary for forming a passivating AlF3 layer and significantly enhanced the anodic stability. On the other hand, carbon-coating the Al foil did not show significant improvements regarding the anodic stability. It was found that the corrosion was time-dependent at a low scan rate, a drastic anodic dissolution of the aluminum was seen at higher temperatures, and the corrosion also became more pronounced. At room temperature, carbon-coated Al foils exhibited increased stability.

We show full Li/S cells with the use of balanced and high capacity electrodes to address high power electro-mobile applications. The anode is made of an assembly comprising of silicon nanowires as active material densely and conformally grown on a 3D carbon mesh as a light-weight current collector, offering extremely high areal capacity for reversible Li storage of up to 9 mAh/cm(2). The dense growth is guaranteed by a versatile Au precursor developed for homogenous Au layer deposition on 3D substrates. In contrast to metallic Li, the presented system exhibits superior characteristics as an anode in Li/S batteries such as safe operation, long cycle life and easy handling. These anodes are combined with high area density S/C composite cathodes into a Li/S full-cell with an ether- and lithium triflate-based electrolyte for high ionic conductivity. The result is a highly cyclable full-cell with an areal capacity of 2.3 mAh/cm(2), a cyclability surpassing 450 cycles and capacity retention of 80% after 150 cycles (capacity loss <0.4% per cycle). A detailed physical and electrochemical investigation of the SiNW Li/S full-cell including in-operando synchrotron X-ray diffraction measurements reveals that the lower degradation is due to a lower self-reduction of polysulfides after continuous charging/discharging.

Smältkarbonatbränslecellen (MCFC) är en högtemperaturbränslecell för stationära applikationer. Den har samma höga totalverkningsgrad som konventionella kraftvärme-anläggningar, men kan byggas i mindre moduler (från 250 kWe). De små modulerna och den bränsleflexibilitet (naturgas, biogas, etanol, diesel) som MCFC har, gör den intressant för exempelvis industrier med organiska restprodukter och höga krav på tillförlitlighet. Den höga temperaturen och närvaron av en saltsmälta gör dock materialdegradering till en viktig faktor för forskning och utveckling inom området. För även om de fälttester som nyligen gjorts har visat på att vissa av degraderingsprocesserna är mindre allvarliga än förväntat, finns fortfarande ett behov av utveckling för att sänka kostnaderna och förlänga livstiden. I första delen av detta arbete undersöktes material för olika delar av cellen inom ramarna för EU-projektet IRMATECH. Materialen ansågs vara interessanta alternativ till de nuvarande materialen på grund av deras lägre kostnad och/eller bättre prestanda. Två alternativa anodströmtilledarmaterial undersöktes. För anodströmtilledaren är korrosionen och den elektriska resistansen av det eventuella oxidlagret nyckelparametrar. Dessa parametrar undersöktes och utvärderades. Fastän de båda alternativa materialen hade oxidlager med låg resistans, fanns indikationer på korrosionsprocesser som kan äventyra materialets långtidsstabilitet. För katodmaterialet, NiO, har upplösningen varit problemet. De upplösta nickeljonerna fälls ut i elektrolyten och bildar dendriter som kan kortsluta cellen. Därför undersöktes nickelupplösningen hos tre alternativa katodmaterial. Det mest lovande materialet, en nickeloxid-katod dopad med magnesium och järn testades i en singelcell för att studera elektrokemisk prestanda, morfologi och områden där nickelutfällning skett. Resultaten visade att prestandan var jämförbar med NiO, men att den mekaniska stabiliteten måste undersökas ytterligare. I ”wet-seal”-området är det rostfria stålet belagt med ett aluminiumskikt för att skydda det från den mycket korrosiva miljön. Tillverkningsprocesserna för dessa aluminiumbeläggningar har hittills varit dyra och komplexa. Därför utvärderades en alternativ tillverkningsprocess. Beläggningen, studerad i både reducerande och oxiderande miljö visade en tendens till att spricka och därmed exponera det underliggande rostfria stålet. Detta berodde troligtvis på en manuell beläggningsprocess som resulterade i ett inhomogent ytskikt. I den andra delen av arbetet föreslogs en alternativ tillverkningsmetod, baserad på nyligen publicerade resultat där man elektrodeponerat aluminium från jonvätskor. Dessa har ett större katodiskt fönster än vatten och möjliggör därför elektrodeponering av elektropositiva material. För att göra processen industrivänlig provades ett alternativ till den vanligen använda aluminiumtrikloriden. Det visade sig dock att påverkan av miljön på stabiliteten hos jonvätskan behövde undersökas innan några material kunde tillverkas. Vatten i kombination med syre visade sig ha en stor inverkan på den katodiska strömtätheten. I frånvaro av dessa komponenter var jonvätskan mycket stabil. / The Molten Carbonate Fuel Cell (MCFC) is a high temperature fuel cell for stationary applications. It has the same high over-all efficiency (90%) as traditional combined heat and power plants, but MCFC can be built in small modules (from 250 kWe). The small modules in combination with fuel flexibility (natural gas, biogas, ethanol, diesel) makes MCFC an interesting alternative for industries with organic waste and high demands for reliability. The high temperature (650 °C) and the presence of molten salt result however in material degradation. Corrosion and dissolution of the materials used have been the challenge for MCFC. Although long-term field trials have shown that some of the material problems are not as severe as first believed, further material development is necessary to decrease the cost and prolong the life-time. In the first part of this work, materials for different parts of the cell were tested within the EU project IRMATECH. The materials were interesting alternatives to the state-of-the-art materials due to their lower cost and/or better performance. Two alternative anode current collector materials were tested. For the anode current collector the corrosion and electrical resistance of the possible oxide layer are key parameters. These parameters were investigated and evaluated. Although both the materials showed a low resistance, there were indications of corrosion processes which could affect the life-time of the material. For the cathode material, NiO, the dissolution of the material has been a problem. The dissolved nickel ions precipitate in the electrolyte and form conductive nickel dendrites that eventually short-circuit the cell. Therefore, the nickel dissolution of three alternative cathode materials was tested. The most promising material, a NiO doped with magnesium and iron, was tested in a single cell to study the electrical performance, the morphology after operation and the area where nickel had precipitated. The results showed that the performance was comparable to NiO, but it is necessary to investigate the mechanical strength of the material further. In the wet-seal area, the stainless steel is coated with an aluminium coating to protect the material from a severe corrosion environment. The production of aluminium coatings has so far been expensive and complex and an alternative coating process was evaluated. The alternative coating, tested in both reducing and oxidising environments showed a tendency to crack and expose the stainless steel to the corrosive environment. This was suggested being due to the manual coating process that resulted in inhomogeneous coatings. In the second part, an alternative process to coat the wet-seal was suggested, based on recently published results where aluminium had been electrodeposited from ionic liquids. These solvents have a wider electrochemical window than water, and electropositive materials can therefore be deposited. To make the coating process suitable for industrial applications, an alternative to the commonly used AlCl3 was tested. It was shown however, that the influence of the environment had to be investigated before any materials could be produced. The environment, especially water in combination with oxygen was shown to influence the cathodic current density. In absence of these components, the ionic liquid was shown to be very stable. / QC 20100906

No description available.

We show full Li/S cells with the use of balanced and high capacity electrodes to address high power electro-mobile applications. The anode is made of an assembly comprising of silicon nanowires as active material densely and conformally grown on a 3D carbon mesh as a light-weight current collector, offering extremely high areal capacity for reversible Li storage of up to 9 mAh/cm(2). The dense growth is guaranteed by a versatile Au precursor developed for homogenous Au layer deposition on 3D substrates. In contrast to metallic Li, the presented system exhibits superior characteristics as an anode in Li/S batteries such as safe operation, long cycle life and easy handling. These anodes are combined with high area density S/C composite cathodes into a Li/S full-cell with an ether- and lithium triflate-based electrolyte for high ionic conductivity. The result is a highly cyclable full-cell with an areal capacity of 2.3 mAh/cm(2), a cyclability surpassing 450 cycles and capacity retention of 80% after 150 cycles (capacity loss <0.4% per cycle). A detailed physical and electrochemical investigation of the SiNW Li/S full-cell including in-operando synchrotron X-ray diffraction measurements reveals that the lower degradation is due to a lower self-reduction of polysulfides after continuous charging/discharging.

Indiana University-Purdue University Indianapolis (IUPUI) / The prevalent applications of energy storage devices have incited wide-spread efforts on production of thin, flexible, and light-weight lithium-ion batteries. In this work, lithium-ion batteries using novel flexible paper-based current collectors have been developed. The paper-based current collectors were fabricated from carbon nanotube (CNT)-coated wood microfibers (CNT-microfiber paper). This thesis presents the fabrication of the CNT-microfiber paper using wood microfibers, coating electrode materials, design and assemblies of battery, testing methodologies, and experimental results and analyses. Wood microfibers were coated with carbon nanotubes and poly(3,4-ethylenedioxythiophene) (PEDOT) through an electrostatic layer-by-layer nanoassembely process and formed into a sheet, CNT-microfiber paper. The CNT loading of the fabricated paper was measured 10.1 μg/cm2 subsequently considered. Electrode material solutions were spray-coated on the CNT-microfiber paper to produce electrodes for the half and full-cell devices. The CNT current collector consists of a network structure of cellulose microfibers at the micro-scale, with micro-pores filled with the applied conductive electrode materials reducing the overall internal resistance for the cell. A bending test revealed that the paper-based electrodes, compared to metal ones, incurred fewer damages after 20 bends at an angle of 300o. The surface fractures on the paper-based electrodes were shallow and contained than metallic-based electrodes. The micro-pores in CNT-microfiber paper structure provides better adherence to the active material layer to the substrate and inhibits detachment while bending. Half-cells and full-cells using lithium cobalt oxide (LCO), lithium titanium oxide (LTO), and lithium magnesium oxide (LMO) were fabricated and tested. Coin cell assembly and liquid electrolyte was used. The capacities of half-cells were measured 150 mAh/g with LCO, 158 mAh/g with LTO, and 130 mAh/g with LMO. The capacity of the LTO/LCO full-cell also was measured 126 mAh/g at C/5 rate. The columbic efficiency of the LTO/LCO full-cell was measured 84% for the first charging cycle that increased to 96% after second cycle. The self-discharge test of the full-cell after charging to 2.7 V at C/5 current rate is showed a stable 2 V after 90 hours. The capacities of the developed batteries at lower currents are comparable to the metallic electrode-based devices, however, the capacities were observed to drop at higher currents. This makes the developed paper-based batteries more suitable for low current applications, such as, RFID tags, flexible electronics, bioassays, and displays. The capacities of the batteries at higher current can be improved by enhancing the conductivity of the fibers, which is identified as the future work. Furthermore, fabrication of an all solid state battery using solid electrolyte is also identified as the future work of this project.