Lithium-aluminum/iron sulfide batteries

Abstract

Lithium-alloy/metal sulfide batteries have been under development at Argonne National Laboratory since 1972. ANL's technology employs a two-phase Li alloy negative electrode, low-melting point LiCl-rich LiCl-LiBr-KBr molten salt electrolyte, and either an FeS or an upper-plateau (UP) FeS 2 positive electrode. These components are assembled in an ‘electrolyte-starved’ bipolar cell configuration. Use of the multi-phase Li alloy ((α+β)-Li-Al and Li 5Al 5Fe 2) negative electrode provides in situ overcharge tolerance that renders the bipolar design viable. Employing LiCl-rich LiCl-LiBr-KBr electrolyte is ‘electrolyte-starved” cells achieves low-burdened cells that possess low area-specific impedance, comparable with that of flooded cells using LiCl-LiBr-KBr eutectic electrolyte. The combination of dense UP FeS 2 electrodes and low-melting electrolyte produces a stable and reversible couple, achieving over 1000 cycles in flooded cells, with high power capabilities. In addition, a new class of stable chalcogenide ceramic/sealant materials was developed. These materials produce high-strength bonds between a variety of metals and ceramics, which make fabrication of lithium/iron sulfide bipolar stacks practical. Bipolar Li-Al/FeS and Li-Al/FeS 2 cells and four-cell stacks using these seals have been built and tested for electric vehicle (EV) applications. When cell performance characteristics are used to model full-scale EV ad hybrid vehicle (HV) batteries, they are projected to meet or exceed the performance requirements for a large variety of EV and HV applications. In 1992, the US Advanced Battery Consortium awarded contracts to ANL and SAFT America to continue the development of the bipolar Li-Al/FeS 2 battery to meet their long-term criteria. Both ANL and sAFT are working together to refine this technology for EV applications and scale it up to larger stacks and fully integrated battery modules.