Alkali metal-metal chloride battery
United States Patent Werth Apr. 15, 1975 ALKALI METAL-METAL CHLORIDE 3,751,298 8/1973 Senderoff 136/6 LF BATTERY [75] Inventor: John J. Werth, Princeton, NJ. Primary Examiner john H M a ck [73] Assignee: ESB Incorporated, Philadelphia, Pa. Assistant Examiner-C. F. LeFevour [22] Filed: Apr. 24, 1974 [21] App]. No.: 463,520  
 [57] ABSTRACT [52] U.S. Cl. 136/6 F; 136/6 LF; 136/20;  
  136/83 T A secondary battery utilizing a molten alkali metal [51] Int. Cl. H0lm 35/00 negative reactant. a metal Chloride positive reactant, a [58] Fi ld f S h 136/20, 6 LE6 F5 6 F molten alkali metal chloraluminate electrolyte and a 136/153-155, 83 R, 83 T selectively-ionically-conductive separator positioned between the negative and the positive reactants. [56] References Cited UNIT STATES PATENTS 13 Claims, 3 Drawing Figures 3,663,295 5/1972 Baker 136/6 FS 7 \z 4 5 Ei&#39;E I&#39;E&#39;I&#39;E -i 1/ X s 2 m m Ski] l m 2 DISCHARGE soo soo COULOMBS M xL  2338 000m 002 009 091 S 009 com com 00 ooN SHEET 2 (If 2 wwmdfuma IV SHOA ALKALI METAL-METAL CHLORIDE BATTERY BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a secondary battery utilizing a molten alkali metal negative reactant with a solid separator, a metal chloride positive reactant and molten salt electrolyte. More particularly, the solid separator is selectively-ionically-conductive with respect to eations of the negative reactant; the positive reactant comprises metal chloride and the molten electrolyte salt comprises molten alkali metal chloraluminate. This battery possesses a voltage potential substantially higher than most batteries now known in the art which utilize molten salt electrolytes and an operating temperature substantially below the operating temperature of other molten salt batteries possessing even relativel higher voltage potentials.  
 2. Description of the Prior Art The use of molten or fused salts as electrolytes in secondary batteries in not new to the art. Such batteries utilize as the electrolyte an inorganic salt composition which is solid and non-conducting at ordinary temperatures. However, when the cell is activated by heating it to a temperature sufficiently high to fuse or melt the electrolyte, the molten electrolyte becomes conductive so that electrical energy may be withdrawn therefrom.  
 Such types of secondary batteries are known for their high energy storage and power output capabilities.  
  Typical secondary batteries of this type utilize a molten alkali metal as the anode-reactant, a cationicallyconductive crystalline structure as a separator electrolyte, and a molten sodium polysulfide or sulfur cathodic reactant-electrolyte which will, during charging and discharging, contain ionic sodium polysulfide. The voltage potential of such a battery is generally in the range of from about 2 to 2.2 volts. It is recognized by those skilled in the art, however, that batteries of this type cannot operate below about 265C because the sodium polysulfide which is present in the cathodic reactantelectrolyte during charging and discharging must be maintained in the molten state and its melting point is as high as 350C depending on the state of the charge. It is equally well-known that this operation of this type of battery at about or above 265C cannot be carried out without attendant problems. For example, sodium polysulfide is a strong oxidizing agent at these elevated temperatures and will tend to effect rapid corrosion, thus seriously reducing the useful life of the battery.  
  A novel secondary battery has now been discovered which utlizes a metal chloride positive reactant in contact with a molten alkali metal chloraluminate electrolyte. This battery can operate at a temperature as low as from about 180C to about 200C and greatly reduce the corrosion problems since sodium chloraluminate at temperatures of from about 180C to about 200C is not a strong oxidizing agent. Additionally, it has been found that the voltage potential of the novel battery of this invention approaches or exceeds 3 volts.  
 SUMMARY OF THE INVENTION positive reactant, and a molten electrolyte on the posi tive reactant side of the solid member. The solid member which separates the negative and positive reactants is selectively-ionically conductive with respect to the cations of the molten alkali metal negative reactant. The molten electrolyte on the positive side of the solid member comprises molten alkali metal chloraluminate. The alkali metal of the negative reactant is also present in the alkali metal chloraluminate.  
 DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic, cross-sectional view of a simple cell in accordance with this invention.  
  FIG. 2 is a graphic representation of the chargedischarge cycle of a cell of this invention.  
  FIG. 3 is a graphic representation of the chargedischarge cycle of another cell of this invention.  
 DESCRIPTION OF THE INVENTION In the operation of the secondary or rechargeable battery of this invention, a high voltage potential is achieved by utilizing a molten alkali metal negative reactant and a metal chloride positive reactant, separating the two by means of a solid member which is selectively-ionically conductive with respect to cations of the molten alkali metal negative reactant, and maintaining on the positive reactant side of the solid separating member a molten electrolyte comprising molten alkali metal chloraluminate.  
  In accordance with this invention, the negative reactant or reductant is an alkali metal or mixture of alkali metals maintained above its melting point when the cell is in operation. The negative reactant is initially heated by any conventional means such as induction heating by electrical means, direct heating, or indirect heat exchange with a suitable heated fluid exchange means. The negative reactant functions as a conductor through which electrons flow to the external circuit during discharge. While no critical limitations are imposed upon the alkali metal selected for use as a negative reactant herein, the desired operating temperatures of this battery are preferably within the range of from about C to about 200C and the metal selected should therefore preferably have a melting point within or below this temperature range. The preferred metal for use as the negative reactant is sodium.  
  The positive reactant of the present invention comprises metal chloride or a mixture of metal chlorides. The specific metal chlorides selected for use will be determined by such factors as the end use to which the battery is to be put; the economics involved, e.g., the cost of starting materials; and the specific alkali metal chloraluminate electrolyte selected for use in the battery. Two criteria must however be satisfied by the metal chloride selected. First, it must be soluble to some extent in the alkali metal chloraluminate electrolyte of the battery; and second, it must be compatible with the other components of the battery, e.g., it must not attack the selectively-ionically-conductive solid member which separates the positive reactant and negative reactant of the battery.  
  So long as these two criteria are satisfied, the selection of the specific metal chloride to be utilized becomes a practical question rather than a critical one, i.e., depending on economics, end use and the like. Useful metal chlorides include antimony trichloride, cupric chloride, ferric chloride, and NiCl antimony trichloride being preferred.  
  The solid member which separates the negative reactant and the positive reactant in the instant invention must be selectively-ionically-conductive with respect to cations of the molten metal negative reactant. Materials suitable for use as the solid separator include glass, beta aluminas and other cation conductive crystalline and/or ceramic materials which are resistant to the molten metal negative reactant and have satisfactorily low resistivities. The preferred separator comprises a beta alumina cationically-conductive crystalline structure consisting essentially of a structural lattice and alkali metal cations which are mobile in relation to said lattice when a difference of electrical potential is provided on opposite sides thereof. The lattice preferably is made of a major portion by weight of ions of aluminum and oxygen and a minor portion by weight of ions by metal having a valence not greater than 2 in crystal lattice combination such as lithium and magnesium. The solid separator member may be prepared by any art known means, see for example, U.S. Pat. No. 3,535,163, so long as the useful end product is selectively-ionically-conductive with respect to the cations of the molten alkali metal negative reactant employed.  
  The electrolyte utilized in the present invention makes possible a substantial reduction in the operating temperature of molten salt batteries as compared with those presently known and used in the art. For example, the operating temperature of the normal molten alkali metal-molten sulfur secondary battery wherein the molten cathodic electrolyte is an ionized combination of sodium and sulfur, i.e., ions of sodium polysulfide, Na S the operating temperature is recognized to be well above 200C and closer to 300C, the melting temperature of sodium pentasulfide being as high as 265C. In marked contract, the battery of the present invention utilizes an electrolyte on the positive reactant side of the solid separating member which comprises molten alkali metal chloraluminate and permits the operation of the instant battery to be carried out at temperatures of 180C to about 200C. It is possible, however, that batteries within the scope of this invention can operate at even lower temperature, since the melting point of the electrolyte is as low as about 125C depending on the state of the charge. By the term molten alkali metal chloraluminate as used herein is meant a mixture of those atoms, molecules, and ions present upon the heating of the particular alkali metal chloraluminates to these operating temperatures, e.g., alkali metal ions, alkali metal chloride molecules, alkali metal chloraluminate molecules, chloride ions, chlorine atoms, AlCl AlClf, and Al Cl These will vary according to the particular alkali metal utilized in the chloraluminate. Sodium is preferred. The advantages of operating at this reduced temperature are of course apparent, e.g., reduced corrosion, increased battery life, and reduced cost of containers and seals, e.g., silicone rubber may be used as a negative gasket seal and teflon as a positive gasket seal.  
  The alkali metals useful as negative reactants in this invention are also useful in the metal chloraluminate. However, the alkali metal utilized in any particular battery as the negative reactant must also be present in at least one of the alkali metals present in the alkali metal chloraluminate of that particular battery.  
  In the battery of the present invention the positive reactant is mixed with the metal chloraluminate by any means known in the art, e.g., it is possible to mix sodium chloride and aluminum chloride together with the positive reactant and heat the resultant mix until ions of sodium chloraluminate and the positive reactant are formed within the cell, i.e., a sodium chloraluminatepositive reactant melt. It should be noted that while the battery of this invention is an alkali metal-metal chloride battery, the metal chloride which is present in the cell, i.e., present in the alkali metal chloraluminatepositive reactant melt within this cell, may be added initially as the metal itself, picking up chloride ions from the ionized sodium chloraluminate upon charging. Therefore, even though a metal was added initially, the positive reactant of the cell will be a metal chloride in the charged state. The metal amount of positive reactant present in this cell is not critical; however, it should be noted that the capacity of the cell is directly related to the amount of metal present in this cell in the positive reactant metal chloride, i.e., the more metal present from the positive reactant metal chloride, the greater the capacity of the cell. The necessary amount which must be added, therefore, can be readily determined by one skilled in the art after the decision has been made as to the desired capacity and the end use to which the cell is to be put.  
  In the operation of the battery of this invention, the separator is a selectively-ionically-conductive separator which separates the negative reactant and the positive reactant both physically and electronically, yet which allows charge aiid discharge through the migration of alkali metal ions (originating from the alkali metal chloraluminate) across the separator. At the negative, the alkali metal yields electrons during discharge, forming alkali metal ions which transport through the separator; the reverse takes place during charge.  
  The positive electrode mechanism involves, during charge, the release of electrons to the external circuit from the metal of the positive reactant metal chloride, whether such metal was originally added as metal or as the metal chloride. Subsequent to this release of electrons, the resultant metal ions will combine with chloride ions present in the melt to form the metal chlorides which constitute the positive reactant of the invention. This faradaic transformation yields high energy. As stated previously herein, the metal chlorides thus formed, which constitute the positive reactant metal chlorides of the battery of the invention, must be to some extent soluble in the molten alkali metal chloraluminate. The actual degree of solubility is, however, not critical. As stated above, during charge, metal atoms of the metal of the positive reactant release electrons to the external circuit. At the same time, however, negatively charged chloride and chloraluminate ions from the alkali metal chloraluminate melt are attracted to the surface of the now positively charged metal ions and combine therewith to form additional metal chloride positive reactant. During discharge the reverse takes place.  
  If increased conductivity is desired, conductive carbon may be added to the alkali metal chloraluminate positive reactant metal chloride melt in any desired amount.  
  Referring now to FIG. 1, a single cell secondary battery according to this invention is constructed having a negative cell container 1 which may be made of any suitable material or materials which are not attacked by molten alkali metal at the operating temperature of the cell, e.g., carbon steel, aluminum, certain ceramics,  
 certain heat and chemical resistant polymers, a suitable glass or an alpha alumina or derivative thereof, all thermally insulated with fiberglass, rockwool or other insulation. Inside container 1 is the molten alkali metal neglector was the steel sodium container. The positive current collector was a 4 inch diameter tungsten rod located in the center of the positive compartment. The current collector was sealed to the Pyrex glass with a ative reactant 2, e.g., sodium. It is separated from the 5 Monel Gyrolok fitting containing Teflon ferrules. alkali metal chloraluminate electrolyte-metal chloride 2, Reactant addition; The cells were first assembled positive reactant melt 3 by ans of a Solid p r ing and sealed to the beta alumina separators before any member 4 which is selectively-ionically-conductive to eact t were added, The sodium was then added in cations. Positive container 8 may be made of any suita m lt n stat into th negativ compartment and able material h as g ceramic, teflon. tungsten sealed with a pipe plug. The positive reactants carand the like. Current c ll c r 5 m y be made of ny bon, metal, chloride, sodium chloride, aluminum trisuitable material such as for example, tungsten wire, hl id were added as powders into the positive carbon rods and the like. Leads 6 and 7 provide means compartment d l d wi h h G l k fitting, for connecting the Ce th an eXternal Circuit and 3. Temperature control: Salt was transformed into a closing the circuit. The external circuit, not further olten c ndition by placing cells in Hoskins furnace shown, y include a voltmeter, ammetef, etc. and temperature was controlled to within 1C by means During the operation of th1s battery, the temperature of an ECS temperature controller. Cells were operated of the alkali metal chloraluminate electrolyte-metal t 200C, These cells contained approximately 1.5 chloride positive reactant melt is maintained at from watt hours f energy; und r these c ditio th t mabou! 130C to about 200C and the Voltage Potential perature was not self sustaining, and a furnace was necof the battery is from about 2.5 to about 3.5 (for SbCl essary to maintain temperature. In cells of reasonable volts. Both the specific energy and the voltage potential size, i.e., l K watt-hour, the temperature will be self will vary with the particular couple used in a specific sustaining once the cell is operating. battery. If for example, a sodium-cupric chloride couplc is used, the theoretical yield will be about 470 EXAMPLE I Whrs/lb. of reactant. 1f the couple is a sodium-ferric chloride couple, the theoretical yield would be about Carbon 0.3g Vulcan XC72-R 360 Whrs/lb. of reactant, while the theoretical yield for Salt 0.56g NaCl, 1.087g A1C1 0.5g CuCl a sodium-antimony trichloride couple would be about 4. Carbons: In all cells, the carbon utilized was Vul- 375 Whrs/lb. of reactant. can XC72-R. This is essentially a non-porous conduc- Mode (D=disch) Current Polarization Time Voltage Temp. Cycle (C=cl1arge) (ma) (1R) (mV) (hrs) Limits 200C 1 D 20 5.8 2 C 20 200 1.67 2.5 3.92 2 D 20 850 1.67 3.60-2.20  
  Efficiency 2.50/3.15 80% 3 C 20 200 1.67 2.50-3.92 3 D 20 750 1.67 3.60-2.20 4 C 20 150 2.30 2.55-3.92 4 D 20 850 2.10 3.40-2.20 4 C 20 200 2.50 2.50-3.90 4 D 10 750 10.20 3 .60-205 5 c 10 200 9.40 2.30-3.90 5 D 10 850 9.50 3.60-2.05 6 C 10 200 9.40 2.20-3.90 e D 10 1000 9.30 3.5 -2.05 7 C 10 150 9.30 2.20-3.90 D 10 1000 9.20 3.55-2.05  
  7 At the 10 ma rate Joule/g (9.4)(01 3000ll2.55 )/3.05 280 Joule/g Average Charge Voltage 3.17  
 Average Discharge Voltage 2.55  
 Efficiency 80.5%  
  C 10 1.42 2.20-2.85 8 C 15 100 3.50 2.87-3.60 8 D 15 800 4.17 3.40-2.05 9 C 15 250 3.91 2.27-3.60 9 D i5 750 3.85 3.40-2.05 10 C 15 250 3.85 2.30-3.60 10 D 15 850 3.80 3.45-2.05 l l C 20 300 2.50 2.30-3.60  
 At the 15 ma rate Joule/g (3.9)(.0l5)(3000)(2.5 )/3.05 172 Joule/g Average Charge Voltage 3.20  
 Average Discharge Voltage 2.45  
 EXAMPLES the positive seal was Teflon. The negative current col- Efficiency 7671 tive furnace black. Its bulk density in air is approximately 0.2 g/cc, making it a very fluffy powder.  
 EXAMPLE 2 Carbon 1.4g washed PWA Salt 4.5g AlCl 25% NaCl), 0.95g FeCl Charge Cycle 50 ma from 1.85V to 4.0V, 7.2 hr  
 rate  
 Discharge Cycle 50 ma from 4.0V to 1.85V, 7.2 hr  
 rate  
 Cycle N0. 14  
 Capacity 2,900 Joule; 575 Joule/g Efficiency 68.5%  
 Temp. 380F (193C) See FIG. 2 for charge-discharge cycle EXAMPLE 3 Carbon 0.45g Vulcan XC72-R Salt 2.22g A1C1 0.64g NaCl, 1.6g SbCl Charge Discharge Current 30 ma Capacity 5,160 Joules; 1,050 Joules/g Efficiency 88% See FIG. 3 for charge-discharge cycle The foregoing detailed description has been given for clarity of understanding only and no unnecessary limitations are to be understood therefrom. The invention is not limited to exact details shown and described for obvious modifications will occur to one skilled in the art.  
  The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:  
 1. A secondary battery comprising in combination:  
 a. a negative reactant consisting essentially of a molten alkali metal;  
 b. a positive reactant comprising metal chloride;  
 c. a solid member separating the negative and positive reactants, said member being selectivelyionically-conductive with respect to cations of said molten alkali metal negative reactant; and  
 d. a molten alkali metal chloraluminate electrolyte on the positive reactant side of the solid member, wherein the alkali metal of the negative reactant is also present in the alkali metal chloraluminate. 2. A battery according to claim 1 wherein the melting point of the electrolyte is from about 125C to 200C. 3. A battery according to claim 1 wherein the alkali metal of the negative reactant and the chloraluminate is sodium.  
  4. A battery according to claim 1 wherein the solid member is beta alumina.  
  5. A battery according to claim 3 wherein the solid member is beta alumina.  
  6. A battery according to claim 5 wherein the melting point of the electrolyte is from about 125C to 200C.  
  7. A battery according to claim 1 wherein the positive reactant is antimony trichloride.  
  8. A battery according to claim 1 wherein the positive reactant is cupric chloride.  
  9. A battery according to claim 1 wherein the positive reactant is ferric chloride.  
 10. A battery according to claim 7 wherein the alkali