Additively-Manufactured Electroactive Carbon-fiber/Phenolic Anodes for Structural Batteries and Grid Storage Craig Milroy, Tim Phillips, Joseph Beaman (Department of Mechanical Engineering, University of Texas, Austin).This presentation describes the electrochemical energy-storage properties of additively -manufactured anodes fabricated from carbon fibers and an electroactive phenolic resin, and demonstrates their utility for three important energy-storage applications:(1) additively-manufactured batteries(2) grid storage(3) structural batteriesPhenolic polymer resins are polymerized by reacting phenols with formaldehyde, and are used in a broad range of applications such as coatings, adhesives, and molded products. Although phenolic resins are technically thermosets, the melting point of most phenolics is lower than their cure (crosslinking) temperature; as a result, many phenolics are melt-processable and may therefore be used as thermoplastic binders for indirect selective laser sintering (SLS) additive manufacturing (AM) processes.Although the uncured phenolic compound is soft and melts at low temperature, the cured polymer has excellent strength/hardness, thermal stability, and chemical resistance/imperviousness. As such, phenolic resins are frequently used in building materials, and are therefore an excellent choice for structural battery applications.In addition, the phenol monomer that forms the basis of phenolic resins is an aromatic molecule with delocalized non-bonding electrons, which allows the hydroxyl moiety on the phenol to undergo reversible hydroxyl/quinine redox conversion. In addition, the polymerization process of phenolic monomers creates methylene bridges between phenol molecules, which preserves the electroactivity of the phenol molecule in its polymerized form. These properties have led to many reports of phenols as “natural” energy storage materials, since there are numerous biological sources of phenolic compounds.We observed the electroactivity of the cured phenolic (GP 5520) when using it as a thermoplastic binder in an indirect SLS fabrication process to produce additively-manufactured graphite anodes. To unambiguously measure the electroactivity of the cured phenolic, we fabricated electrodes by mixing phenolic powder in solid or dissolved form with non-electroactive conductive carbon fibers. The electrodes were fabricated via SLS and then cured to affix the electroactive phenol to the carbon fibers, which provided mechanical strength and served as a current collector for charge injection/extraction . The Figure depicts representative voltage profiles during galvanostatic discharge/charge testing of an SLS-fabricated composite electrode containing carbon fibers and phenolic, and indicates that the material is predisposed to function well as an anode, since the discharge occurs exclusively in a relatively narrow potential range below 1.0 V relative to the Li / Li+ equilibrium potential.The Figure also presents lgalvanostatic cycle performance of the SLS-fabricated electrodes at different rates. As expected, electrodes that were discharged at lower current density produced higher capacity. However, all electrodes exhibited a gradual maturation of capacity that is commonly observed in other electroactive polymers such as polypyrrole and polyanaline. The total number of cycles required to reach stable capacity was inversely proportional to the current density. Overall, the electrodes displayed consistent cycle performance once their discharge capacity stabilized; therefore, to address the observed electrode maturation process, and to definitively evaluate the rate-dependent cycle performance, we utilized rate-capability testing, beginning with low current for a few cycles at the beginning of each cell test, followed by a traditional rate-capability ladder to assess the dependence of capacity on previous cycling history. As shown in the Figure, these tests found that the electrodes produced 200 mAh/g of phenolic at 15 mA/g , and 100 mAh/g phenolic at 75 mA/g. Figure 1
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