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Large Planar Na-β″-Al2O3 Solid Electrolytes for Next Generation Na-Batteries.

Samuel Clark Ligon1, Marie-Claude Bay2, Meike V F Heinz2

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Materials (Basel, Switzerland)
|January 23, 2020
PubMed
Summary

Large diameter planar sodium beta-double-prime alumina (Na-β″-Al2O3) solid electrolytes were successfully fabricated using tape casting. These membranes offer potential for higher power density sodium-ion batteries.

Keywords:
Na-β″-Al2O3molten-salt batteriesplanar cellsodium batteriestape casting

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Ceramic Engineering

Background:

  • Sodium beta-double-prime alumina (Na-β″-Al2O3) is a key solid electrolyte material for sodium-ion batteries.
  • Current manufacturing methods for Na-β″-Al2O3 often limit scalability and cell design.
  • Planar solid electrolytes are desirable for improved cell performance and manufacturability.

Purpose of the Study:

  • To develop a scalable method for producing large-diameter, thin planar Na-β″-Al2O3 solid electrolytes.
  • To evaluate the properties of Na-β″-Al2O3 produced via tape casting.
  • To assess the potential of planar Na-β″-Al2O3 membranes for advanced battery designs.

Main Methods:

  • Na-β″-Al2O3 was processed into a slurry and tape cast to produce long tapes.
  • Large diameter discs (140 mm) were punched, stacked, and laminated using a hydraulic press.
  • Binder burnout and sintering were conducted within MgO spinel encapsulations to prevent Na2O volatilization.

Main Results:

  • Successfully prepared large diameter (> 100 mm) planar Na-β″-Al2O3 solid electrolytes with thicknesses of 1.0–1.5 mm.
  • Electrical conductivity and flexural strength measurements on tape-cast samples were consistent with conventionally produced BASE.
  • The tape casting process yielded meters of electrolyte tape, indicating scalability.

Conclusions:

  • Tape casting is a viable and scalable method for producing large-diameter, thin planar Na-β″-Al2O3 solid electrolytes.
  • Planar Na-β″-Al2O3 membranes enable novel cell designs with predicted higher power densities and improved stacking efficiency.
  • This advancement could lead to more efficient and compact sodium-ion battery technologies.