Granted Patent B2

US 12,368,188 · App. 16/634,819 · Granted Jul 22, 2025

Inventors: Jinchao Huang (New York, NY); Gautam G. Yadav (New York, NY); Michael Nyce (New York, NY); Sanjoy Banerjee (New York, NY)

Assignee: RESEARCH FOUNDATION OF THE CITY UNIVERSITY OF NEW YORK

H01M10/24H01M50/403H01M50/414H01M50/431H01M50/44H01M50/451H01M50/457H01M50/489H01M2300/0014

Abstract

Claims (37)

1. An alkaline battery comprising:

an anode;

a cathode;

a separator disposed between the anode and the cathode, wherein the separator comprises at least one ion selective layer comprising a dispersion of a polymer and an ion selective material mixed into the dispersion, wherein the ion selective material comprises at least one of graphene, graphene oxide, reduced graphene oxide, functionalized graphene, or combinations thereof, wherein at least a portion of the polymer is cross-linked, and wherein sheets of the ion selective material are horizontally aligned and orientated in layers on top of each other within the ion selective layer, wherein the sheets of the ion selective material are horizontally aligned when planes of the sheets of the ion selective material are parallel to a face of the at least one ion selective layer; and

an electrolyte in fluid communication with the anode, the cathode, and the separator.

2. The alkaline battery of claim 1 , wherein the ion selective layer is configured to selectively block zincate ions.

3. The alkaline battery of claim 2 , wherein the ion selective layer is applied with one or more non-selective separator membranes between the anode and the cathode.

4. The alkaline battery of claim 3 , wherein the non-selective separator membranes are nonwovens or polymer films fabricated from nylon, polyester, polyethylene, polypropylene, poly(tetrafluoroethylene) (PTFE), poly(vinyl chloride) (PVC), polyvinyl alcohol, cellulose, or combinations thereof.

5. The alkaline battery of claim 1 , wherein at least one of the anode or the cathode comprises the ion selective material as a layer or a coating on the anode or the cathode.

6. A method for producing a composite ion selective membrane for an alkaline battery, the method comprising:

dispersing a polymer into a solvent to form a polymer dispersion;

dispersing an ion selective material into the solvent;

mixing the ion selective material into the polymer dispersion to form a mixture;

aligning and orienting the ion selective material within the polymer dispersion;

cross-linking at least a portion of the polymer; and

forming the composite ion selective membrane for the alkaline battery out of the mixture, wherein the ion selective material comprises at least one of graphene, graphene oxide, reduced graphene oxide, functionalized graphene, or combinations thereof, and wherein sheets of the ion selective material are horizontally aligned and orientated in layers on top of each other within the composite ion selective membrane based on the aligning and orienting, wherein the sheets of the ion selective material are horizontally aligned when planes of the sheets of the ion selective material are parallel to a face of the composite ion selective membrane.

7. The method of claim 6 , wherein the polymer is poly(vinyl alcohol), poly(acrylic acid), carboxymethyl cellulose, polypropylene, polyethylene, poly(vinyl chloride) (PVC), poly(tetrafluoroethylene) (PTFE), or combinations thereof.

8. The method of claim 6 , wherein the solvent is water, an organic solvent, or a combination thereof.

9. The method of claim 6 , wherein the ion selective material is a graphene material.

10. The method of claim 6 , wherein the step of dispersing the polymer comprises stirring, ultrasonication, or vibration mixing.

11. The method of claim 6 , wherein the ion selective material comprises a functionalized graphene material, and wherein the step of dispersing the ion selective material comprises stirring, ultrasonication, or vibration mixing.

12. The method of claim 7 , wherein the ion selective material comprises a functionalized graphene material, and wherein the polymer dispersion contains 0.1% to 10% functionalized graphene.

13. The method of claim 6 , wherein the composite ion selective membrane is formed through vacuum assisted filtration, pressure assisted filtration, solution casting with air drying or vacuum drying, spin coating, or forming the membrane at an air-liquid interface.

14. The method of claim 6 , wherein the composite ion selective membrane has a thickness in a range from 1 nm to 1 mm.

15. The method of claim 6 , wherein the composite ion selective membrane has a structure of graphene monolayers laminated on top of each other, with or without polymer chains in between.

16. The method of claim 6 , wherein the composite ion selective membrane is coated with one or more layers of polymers.

17. The method of claim 16 , wherein the one or more layers of polymer are poly(vinyl alcohol), poly(acrylic acid), carboxymethyl cellulose, polypropylene, polyethylene, poly(vinyl chloride) (PVC), poly(tetrafluoroethylene) PTFE), or combinations thereof.

18. A separator for an alkaline battery comprising:

at least one ion selective layer comprising a dispersion of a polymer and an ion selective material mixed into the dispersion, wherein the ion selective material comprises at least one of graphene, graphene oxide, reduced graphene oxide, functionalized graphene, or combinations thereof positioned between an anode and a cathode in the battery, wherein at least a portion of the polymer in the ion selective layer is cross-linked, and wherein sheets of the ion selective material are horizontally aligned and orientated in layers on top of each other within the ion selective layer, wherein the sheets of the ion selective material are horizontally aligned when planes of the sheets of the ion selective material are parallel to a face of the at least one ion selective layer,

wherein the separator is disposed in the alkaline battery.

19. The separator of claim 18 , wherein the ion selective layer is configured to selectively block zincate ions.

20. The separator of claim 18 , wherein the ion selective layer is applied with one or more non-selective separator membranes between the anode and the cathode.

21. The separator of claim 18 , wherein the ion selective layer comprises one or more polymer layers coated on a layer with the ion selective material.

22. The separator of claim 21 , wherein the polymer layers comprise nylon, polyester, polyethylene, polypropylene, poly(tetrafluoroethylene) (PTFE), poly(vinyl chloride) (PVC), polyvinyl alcohol, cellulose, or any combination thereof.

23. The method of claim 6 , wherein the ion selective material is a graphene oxide material.

24. The alkaline battery of claim 1 , wherein the separator comprises a laminated graphene oxide and a polyvinyl alcohol membrane.

25. The alkaline battery of claim 24 , wherein the anode comprises zinc and the cathode comprises manganese dioxide.

Assignments (1)

Continuity (2)

References Cited (26)