Development of a high-rate, rechargeable bipolar LiAl/FeS{sub 2} battery

Materials refinements have improved bipolar Li-Al/FeS{sub 2} batteries for power-demand applications. Current technology uses a two-phase Li-alloy cathode, LiCl-LiBr-KBr electrolyte, and an upper-plateau (UP) FeS{sub 2} anode for a battery operated at 440 C; the battery is in sealed bipolar form. The two-phase Li alloy ({alpha}+{beta} Li-Al and Li{sub 5}Al{sub 5}Fe{sub 2}) cathode provides in situ overcharge tolerance that makes the bipolar design viable. The use of LiCl-rich LiCl-LiBr-KBr electrolyte in ``electrolyte-starved`` cells achieves low-burdened cells with low area-specific impedance, with MgO powder separator. Combining dense UP FeS{sub 2} electrodes with a CuFeS{sub 2} additive and a LiI-modified electrolyte produces a stable and reversible couple, with high power capabilities. Long cycle life depends on peripheral seals for each cell in the bipolar stack. Seal composition is based on stable sulfide ceramic/sealant materials that produce strong bonds between metals and ceramics. Using these seals, bipolar Li-Al/FeS{sub 2} cells and four-cell stacks are being built and tested (25 Ah, 13-cm dia). Adding 5 mol% LiI to the electrolyte increased specific energy by 50% under a 140 W/kg, constant power C/1 rate and a 544 W/kg power pulse (8-s) schedule. Cell capacity under the high-power pulse-demand approximates the C/3 rate discharge capacity. Cell specific energy is 155 Wh/kg at the C/3 rate.