IP Library › Granted Patent US 12,261,298

Granted Patent B2

US 12,261,298 · App. 17/437,202 · Granted Mar 25, 2025

Polymer-inorganic solid-electrolyte interphase for stable metal batteries under lean electrolyte conditions

Inventors: Donghai Wang (University Park, PA); Tom Mallouk (University Park, PA); Yue Gao (University Park, PA)

Assignee: The Penn State Research Foundation

H01M4/602 H01M4/382 H01M4/8668 H01M10/0525 H01M10/0562 H01M10/44 H01M2300/0065

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Quick Facts

Patent No.: US 12,261,298
App. No.: 17/437,202
Granted: Mar 25, 2025
Kind: B2

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USPTO Patent Center↗ Full Patent PDF↗

Abstract

Disclosed is a reactive polymer composite comprising a reactive functionalized polymer having a main polymer chain with functionalization along the main polymer chain, wherein the functionalization comprises one or more functional groups that are configured to react with a metal electrode to form a polymeric metal salt and one, or more functional groups configured to electrochemically decompose. Also disclosed are electrodes and batteries comprising the same. Also disclosed are methods of making the same.

Claims (62)

1. A reactive polymer composite comprising a reactive functionalized polymer having a main polymer chain with functionalization along the main polymer chain, wherein the functionalization comprises one or more functional groups that are configured to react with a metal electrode to form a polymeric metal salt and one or more functional groups configured to electrochemically decompose to generate a stable solid electrolyte interphase (SEI) layer on the metal electrode.

2. The reactive polymer composite of claim 1 , wherein the reactive polymer composite further comprises a filler from greater than 0 to about 60 wt %, and wherein the filler comprises graphene oxide, reduced graphene oxide, borophene, molybdenite, silicon oxide, metal oxide, metal halides, or any combination thereof.

3. The reactive polymer composite of claim 1 , wherein the main polymer chain comprises an aliphatic backbone, a polyaromatic backbone, a polycyclic backbone, a polysaccharide backbone, or any combination thereof.

4. The reactive polymer composite of claim 1 , wherein the one or more functional groups are linked to the main polymer chain via linker L and comprise one or more of a sulfonyl halide, a metal sulfonate, a cyclic sulfone, a cyclic ether, a cyclic carbonate, a linear ether, an epoxide group, a cyclic acetal group, a cyclic carbonate ester group, SO 2 F group, NH—SO 2 —F, N(R′)—SF 3 group, SO 2 —N(F)—SO 2 —R 2 group, substituted or unsubstituted fluoropyridinium triflate; wherein

L is independently selected from null, C 1 -C 10 alkyl, C 1 -C 10 alkoxy, C 6 -C 14 aryl, C 1 -C 14 heteroaryl, C 6 -C 14 aryloxy, imidazole, —NH—, pyridine, and wherein L is optionally substituted with C 1 -C 10 alkyl, C 1 -C 10 alkoxy, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 6 -C 14 aryl, C 1 -C 14 heteroaryl, amino, carbonyl, ester, ether, halide, carboxyl, hydroxy, nitro, cyano, silyl, sulfo-oxo, sulfonyl, sulfone, sulfoxide, thiol, or phosphonyl; and

wherein R 1 and R 2 , each independent of the other, selected from hydrogen, C 1 -C 10 alkyl, C 1 -C 10 alkoxy, C 6 -C 14 aryl, C 1 -C 14 heteroaryl, C 6 -C 14 aryloxy, imidazole, amine, pyridine, and wherein each of R 1 and R 2 independent of the other, is optionally substituted with C 1 -C 10 alkyl, C 1 -C 10 alkoxy, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 6 -C 14 aryl, C 1 -C 14 heteroaryl, amino, carbonyl, ester, ether, halide, carboxyl, hydroxy, nitro, cyano, silyl, sulfo-oxo, sulfonyl, sulfone, sulfoxide, thiol, or phosphonyl.

5. The reactive polymer composite of claim 1 , wherein the reactive functionalized polymer comprises one or more monomeric units selected from:

wherein

R 3 is independently selected at each occurrence from an epoxide group; a cyclic acetal group;

a cyclic carbonate group; and

R 4 is hydrogen; or

R 3 and R 4 are brought together with the carbons to which they are attached to form a cyclic carbonate group.

6. The reactive polymer composite of claim 1 , wherein the polymer comprises one or more of

wherein n is an integer number from 1 to 100, and wherein

x and y each, independently, is an integer number from 1 to 100 and present in a ration from 1:10 to 10:1.

7. The reactive polymer composite of claim 1 , wherein the metal electrode comprises lithium, sodium, zinc, or any alloys thereof.

8. An electrode comprising:

a) an active electrode material comprising a metal;

b) a reactive polymer composite comprising a reactive functionalized polymer having a main polymer chain with functionalization along the main polymer chain, wherein the functionalization comprises one or more functional groups that are configured to react with a metal electrode to form a polymeric metal salt and one or more functional groups configured to electrochemically decompose; and

c) a solid-electrolyte interphase layer, wherein the solid-electrolyte interphase layer comprises the polymeric metal salt, and

wherein the solid-electrolyte interphase layer is a product of a reaction between the metal and the reactive polymer composite and/or

wherein the solid-electrolyte interphase layer is a product of the decomposition of one or more functional groups.

9. The electrode of claim 8 , wherein the reactive polymer composite further comprises a filler from greater than 0 to about 60 wt %, and wherein the filler comprises graphene oxide, reduced graphene oxide, borophene, molybdenite, silicon oxide, metal oxide, metal halides, or any combination thereof.

10. The electrode of claim 8 , wherein the main polymer chain comprises an aliphatic backbone, a polyaromatic backbone, a polycyclic backbone, a polysaccharide backbone, or any combination thereof.

11. The electrode of claim 8 , wherein the one or more functional groups are linked to the main polymer chain via linker L and comprise one or more of a sulfonyl halide, a metal sulfonate, a cyclic sulfone, a cyclic ether, a cyclic carbonate, a linear ether, an epoxide group, a cyclic acetal group, a cyclic carbonate ester group, SO 2 F group, NH—SO 2 —F, N(R 1 )—SF 3 group, SO 2 —N(F)—SO 2 —R 2 group, substituted or unsubstituted fluoropyridinium triflate; wherein

12. The electrode of claim 8 , wherein the reactive functionalized polymer comprises one or more monomeric units selected from:

wherein

R 3 is independently selected at each occurrence from an epoxide group; a cyclic acetal group;

a cyclic carbonate group; and

R 4 is hydrogen; or

R 3 and R 4 are brought together with the carbons to which they are attached to form a cyclic carbonate group.

13. The electrode of claim 8 , wherein the polymer comprises one or more of

wherein n is an integer number from 1 to 100, and wherein

x and y each, independently, is an integer number from 1 to 100 and present in a ratio from 1:10 to 10:1.

14. The electrode of claim 8 , wherein the metal comprises lithium, sodium, zinc, or any alloys thereof.

15. The electrode of claim 8 , wherein the solid-electrolyte interphase layer further comprises one or more metal salts, and wherein the solid-electrolyte interphase has a thickness from about 50 nm to about 200 nm.

16. The electrode of claim 8 , wherein the electrode is configured to maintain substantially defect-free morphology for about 600 charge/discharge cycles in an electrolyte solution.

17. The electrode of claim 8 , wherein the solid-electrolyte interphase layer is substantially stable at a temperature from about −10° C. to about 50° C.

18. The electrode of claim 8 , wherein the electrode further comprises a 3-D host material.

19. A battery comprising:

a) the anode material of claim 8 :

b) an electrolyte; and

c) a cathode, and

wherein the battery exhibits substantially stable cycling for at least 600 cycles.

20. The battery of claim 19 , wherein the electrode is configured to maintain substantially defect-free morphology for about 600 charge/discharge cycles in the electrolyte.

21. The battery of claim 19 , wherein the battery exhibits an electrolyte-to-capacity ratio of less than about 15 μL mAh −1 .

22. The battery of claim 19 , wherein the battery exhibits a coulombic efficiency for a metal deposition greater than about 95% when measured at a predetermined current density.

23. The battery of claim 22 , wherein the predetermined current density is from about 0.1 mA cm −2 to about 10 mA cm −2 .

24. The battery of claim 19 , wherein the battery exhibits electrolyte retention of at least 70% after at least 100 cycles.

25. A method comprising:

disposing a reactive polymer composite on an active electrode material, wherein the reactive polymer composite comprises a reactive functionalized polymer having a main polymer chain with functionalization along the main polymer chain, wherein the functionalization comprises one or more functional groups that are configured to react with a metal electrode to form a polymeric metal salt and one or more functional groups configured to electrochemically decompose; and wherein the active electrode material comprises a metal; and

forming an electrode comprising a solid-electrolyte interphase layer comprising the polymeric metal salt, wherein the solid-electrolyte interphase layer is a product of a reaction between the metal and the reactive polymer composite and/or

wherein the solid-electrolyte interphase layer is a product of the decomposition of one or more functional groups.

26. The method of claim 25 , wherein the metal is deposited on a 3-D host material to form the active electrode material.

27. A method comprising:

providing

a) the electrode of claim 8 , wherein the electrode is an anode;

b) an electrolyte; and

c) a cathode

to form a battery exhibiting substantially stable cycling for at least 600 cycles.

Assignments (2)

ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 8, 2022

From: WANG, DONGHAI; MALLOUK, TOM; GAO, YUE

To: THE PENN STATE RESEARCH FOUNDATION

Reel/Frame 059348/0479 →

CONFIRMATORY LICENSE Recorded Feb 15, 2022

From: PENNSYLVANIA STATE UNIVERSITY

To: UNITED STATES DEPARTMENT OF ENERGY

Reel/Frame 059115/0153 →

Continuity (2)

Provisional Application 62815596 · Mar 8, 2019

Related Publication 20220173396A1 · Jun 2, 2022

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