New Route to Battery Grade NaPF₆ for Na-Ion Batteries: Expanding the Accessible Concentration

Sodium-ion batteries represent a promising alternative to lithium-ion systems. However, the rapid growth of sodium-ion battery technology requires a sustainable and scalable synthetic route to high-grade sodium hexafluorophosphate. This work demonstrates a new multi-gram scale synthesis of NaPF₆ in which the reaction of ammonium hexafluorophosphate with sodium metal in THF solvent generates the electrolyte salt with the absence of the impurities that are common in commercial material. The high purity of the electrolyte (absence of insoluble NaF) allows for concentrations up to 3 M to be obtained accurately in binary carbonate battery solvent. Electrochemical characterization shows that the degradation dynamics of sodium metal-electrolyte interface are different for more concentrated (>2 M) electrolytes, suggesting that the higher concentration regime (above the conventional 1 M concentration) may be beneficial to battery performance.