Manufacturing Method for Large-Format, Rechargeable Zn-Sponge Electrodes

Tuesday, 15 October 2019: 14:20
Room 218 (The Hilton Atlanta)
B. J. Hopkins (NRC Postdoctoral Associate, NRL), C. N. Chervin, J. F. Parker, J. W. Long, and D. R. Rolison (U.S. Naval Research Laboratory)
Rechargeable zinc (Zn) batteries are safe, sustainable, and energy-dense alternatives to Li-ion batteries. Recent advances, such as monolithic Zn-sponge electrodes, have enabled long cycle lives by suppressing the formation of short-circuiting dendrites even after deep levels of discharge and charge. A substantial barrier, however, to their widespread adoption has been their poor mechanical integrity. Our previous Zn-sponge electrodes had uniaxial compressive strengths near 0.01 MPa. With such a compressive strength, the sponge electrode can break under its own weight if cantilevered with planar dimensions beyond 1 cm with a thickness of 0.2 cm. If the mechanical strength were enhanced while preserving electrochemical performance, Zn-sponge electrodes could be used in next-generation grid-storage, electric-vehicle, and personal-electronic batteries. Here, we present a manufacturing process that optimizes the reinforcing zinc-oxide shell over the fused zinc-sponge core. The presence of the oxide shell boosts the compressive strength of the sponge with respect to our previous version by 9,900%, yielding a plateau stress of 1 MPa. This increase in strength enables the fabrication of large, thin Zn-sponge electrodes (12×12×0.2 cm) for large-format applications. When paired with a nickel electrode, the reinforced Zn-sponge electrode displays rechargeability and high system energy density.