Enhanced Discharge Capacity in Carbon Felt Electrodes for Aqueous Aluminium-Ion Half-Cells
Authors: Melzack Nicole , Wills Richard G A , Cruden Andrew J 
Published: August 2024

Diversifying the battery technology in use is an important step in ensuring a sustainable transition to a carbon neutral society, and reducing the emissions associated with lithium-ion cell manufacture. Aluminium is an attractive material for battery applications due to its high theoretical volumetric charge storage capacity of 8046 mA h cm−3 compared to lithium’s 2061 mAh cm-3 and relative abundance in the earth’s crust (1). Aqueous Al-ion batteries are one of many metal-ion systems being investigated utilising water as the electrolyte (2). Further, there are well-established mining, processing, and recycling routes for aluminium, with Li-ion battery recycling still in its infancy (3). Using aqueous electrolytes further provides improved safety as fire risk is reduced, and manufacturing costs are also reduced (4).
The substrate on which the electrode material is applied impacts how it is utilised within an electrochemical system. The substrate provides both a shape to the electrode, as well as the material itself forming part of the system, and common substrates double as current collectors e.g. thin metal foils, but carbon polymers have also been explored as a substrate (5, 6). Carbon felt is a conductive substrate, with thin fibres of 5-10 μm diameter, providing a flexible porous structure and large surface area for the active material ‘ ink’ to adhere (0.4 m2 g-1 (7)) . Carbon based electrodes have been assessed in a non-aqueous Al-ion cathodes (8), with varying performance metrics based on the structure and make-up of the electrode, however, these were not investigated as a substrate for further electrode ink. In adding the ink to the carbon felt, the electrode becomes an effective 3D-matrix electrode.
This poster explores the use of such 3D-matrix electrodes in order to increase the amount of active material utilised within the aq. Al-ion battery system (9) – a key requirement in reducing the environmental impacts of the battery overall (5), and a means for increasing the capacity of an individual electrode without increasing the overall volume. The cell described in (10) has a carbon-polymer electrode substrate, anatase TiO2 negative electrode and a copper hexacyanoferrate (CuHCF) positive electrode, with the electrolyte being 1 M AlCl3 + 1 M KCl. While the CuHCF redox reaction is partially understood, the negative electrode mechanism has not been fully elucidated. A theorised surface reaction, and pseudo-capacitance of the TiO2 electrode in the aq. Al-ion battery would benefit from an increased surface area of the electrode provided by the carbon felt. Therefore, a key factor in achieving the optimum utilisation of active material is not purely an increase of TiO2 in the electrode, but an increase in the surface area in contact with the electrolyte. Key findings presented show that the lower active material loadings result in a higher discharge capacity for both the positive and negative electrodes, with values reaching an order of magnitude higher than seen for the 2D electrodes studied in the past. For the TiO2 electrode, we see 205.0 mAh g-1 @978 mA g-1 (1.81 mg cm-2 active material loading) and for the CuHCF, 259 mA h g-1 @ 1256.8 mA g-1 (2.5 mg cm-2 active material loading).

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