Sodium-ion battery materials

Overview

Sodium-ion batteries (SIBs) store energy by reversibly inserting and extracting sodium ions between a cathode and an anode through an electrolyte. Compared with lithium, sodium is abundant and attractive for cost-sensitive stationary storage and supply-chain resilience. In research and pilot development, the choice of active material strongly influences voltage profile, reversible capacity, first-cycle efficiency, rate capability, safety margin, and long-term stability.

In practice, most Na-ion systems pair a carbon anode (commonly hard carbon) with one of several cathode families: layered oxides, Prussian blue analogues (PB/PW), or polyanionic phosphates. Each family offers different trade-offs between energy density, moisture sensitivity, processing behaviour (slurry coating/compaction), and ageing mechanisms.

Key Capabilities

With the right sodium-ion materials set, you can:

• Screen anode/cathode combinations for reversible capacity and coulombic efficiency
• Compare voltage hysteresis and plateau behaviour (diagnostic for Na storage mechanisms)
• Evaluate rate performance at different C-rates and cut-off windows
• Study degradation drivers (particle cracking, surface reactivity, electrolyte decomposition)
• Tune electrode formulation (binder, conductive carbon, loading, porosity, calendering)
• Benchmark batch-to-batch purity/PSD impacts on repeatability
• Develop protocols for moisture control, drying, and storage of sensitive powders
  
  

Typical Applications

• Coin-cell and pouch-cell development for Na-ion cathode/anode screening
• Hard-carbon anode optimisation (first-cycle loss, capacity retention, fast-charge behaviour)
• Cathode comparison: layered oxide vs Prussian analogues vs phosphate systems
• Electrolyte/additive studies targeting SEI/CEI stabilisation
• Quality control studies (PSD, surface area, impurity limits) for scale-up readiness
• Academic and industrial feasibility studies for stationary storage chemistries
  
  

Integration & Compatibility

Sodium-ion materials research typically integrates with:

• Battery cycling and formation workflows via /battery-test-systems
• Mechanistic studies using /potentiostats-galvanostats for CV, GCD method development, and impedance diagnostics
• Cell hardware and electrode preparation through /electrochemical-cells (coin/pouch fixtures, lab cells, current collectors)
  Choose materials alongside compatible binders, conductive additives, and cell formats to ensure results translate from screening to prototype builds.
  
  

Why Choose ScienceGears (AU & NZ)

ScienceGears supports researchers across Australia and New Zealand with practical guidance on material selection, handling and storage, electrode processing considerations, and test planning. We help align material choice with your target metrics (capacity, efficiency, stability, rate) and your available cell format, cycling protocol, and lab infrastructure—so your results are defensible and repeatable.

2) PRODUCT FAMILIES & MODELS 

Hard Carbon Anodes

Hard carbon is a leading Na-ion anode due to practical capacity and good low-temperature/fast-charge potential. Morphology and particle size strongly affect slurry rheology, tap density, first-cycle efficiency, and rate behaviour.

• Na-HC01 Irregular Hard Carbon — Where it fits: general screening; irregular particles can favour higher surface reactivity and faster kinetics (with careful SEI control).
• Na-HC02 High Sphericity Hard Carbon — Where it fits: improved packing/tap density and coating uniformity; often preferred when translating to higher loading electrodes.
  
  

Layered Oxide Cathodes

Layered transition-metal oxides are widely studied for strong energy density potential and tunable voltage via composition. They can be sensitive to moisture and require controlled processing.

• TOB-NMO Sodium Nickel-manganese Oxides (NaNi₀.₅Mn₁.₅O₄) — Where it fits: voltage/capacity benchmarking in half-cell testing; useful for rate comparisons across PSD batches.
• TOB-NFMS Nickel-iron Manganese Acid Sodium Laminate Oxide — Where it fits: multi-metal layered oxide option for balancing capacity and stability; suitable for comparative ageing studies.
• TOB-NFM Sodium Manganese Ferrate (Na₂/₃(Fe₁/₂Mn₁/₂)O₂) — Where it fits: Fe/Mn-based layered oxide for cost-leaning cathode research and cycling optimisation.
  
  

Polyanionic Phosphate Cathodes

Polyanionic frameworks (e.g., phosphates) are valued for structural robustness and safer voltage behaviour, often with excellent cycling stability.

• NVP Carbon-Coated Sodium Vanadium Phosphate (Na₃V₂(PO₄)₃) — Where it fits: stable cycling and power-leaning cathode research; carbon coating supports conductivity and rate tests.
  
  

Prussian Blue Analogues (PB/PW)

Prussian systems are attractive for high-rate capability and aqueous-processable routes in some workflows, but can be sensitive to water content and defect chemistry.

• PBAs Prussian Blue Powder — Where it fits: cathode screening where high rate and practical synthesis routes are priorities; monitor pH/moisture and PSD effects.
• PW Prussian White Powder — Where it fits: a more reduced/sodiated Prussian form used for specific performance targets; handling and storage discipline matters.
  
  

3) HOW TO CHOOSE 

Start by defining your priority: energy density vs power vs lifetime. Select the cathode family accordingly (layered oxide for higher voltage potential, phosphate for stability, PB/PW for rate-friendly behaviour). Then match particle size distribution to your coating method and target loading, and consider surface area/tap density for electrode density and repeatability. For anodes, decide between irregular vs spherical hard carbon based on first-cycle efficiency targets, packing density, and scale-up intent. Finally, confirm handling needs (moisture sensitivity, drying/storage) before ordering.

4) FAQs 

Q1: What are sodium-ion battery materials?

Sodium-ion battery materials are the active electrode powders (anode and cathode) that reversibly store sodium ions during charge and discharge. In most lab cells, the anode is hard carbon and the cathode is a layered oxide, Prussian blue analogue, or polyanionic phosphate. Material choice determines capacity, voltage profile, first-cycle efficiency, rate capability, and ageing behaviour.

Q2: How does hard carbon work as a sodium-ion anode?

Hard carbon stores sodium through a combination of adsorption at defects/surfaces and insertion into disordered carbon domains, often producing a sloping region and a lower-voltage plateau. Particle morphology and surface area influence SEI formation and first-cycle loss. Spherical grades can improve packing and coating consistency, while irregular grades are common for broad screening.

Q3: Which cathode chemistry should I choose: layered oxide, PB/PW, or phosphate?

Choose layered oxides when you need higher voltage potential and composition tuning, but plan for moisture control and careful processing. Choose Prussian blue/Prussian white when high rate capability and practical performance are priorities, while monitoring water/defects that impact stability. Choose polyanionic phosphates when cycling robustness and safer behaviour are more important than maximum energy density.

Q4: What particle size data matters most when selecting these powders?

For most slurry-cast electrodes, D10/D50/D90 and overall PSD shape affect dispersion, viscosity, coating uniformity, porosity, and calendering response. Finer powders can boost kinetics but increase surface reactivity (more side reactions), while coarser powders may improve stability but limit rate. If you are scaling loading, also consider tap density and surface area.

Q5: Are Prussian blue materials sensitive to moisture and handling?

Yes—PB/PW materials can contain structural water and can be sensitive to humidity, which may shift electrochemistry and reproducibility. Good practice includes storing powders sealed and dry, controlling drying conditions, and documenting moisture exposure in your methods. If you are correlating ageing behaviour, keep handling consistent across batches and repeats.

Q6: What test systems and methods are typically used with sodium-ion materials?

Most groups start with coin-cell cycling to benchmark capacity, efficiency, and retention, then move to protocol development using /potentiostats-galvanostats (CV, impedance, and controlled current methods). For longer-term studies, formation/cycling is run on /battery-test-systems with consistent cut-offs, rest steps, and temperature control to improve comparability.

Q7: Can ScienceGears help with selection and setup in Australia and New Zealand?

Yes. We support AU & NZ researchers with practical selection guidance (matching materials to targets and equipment), handling/storage considerations, and test planning for repeatable datasets. If you share your cell format, cut-off window, and target metrics (power vs energy vs life), we can help narrow the most suitable material family and model options.

Q8: What safety or operating considerations apply to sodium-ion material testing?

Sodium-ion cells still require careful control of moisture/oxygen exposure (especially for sensitive cathodes), correct electrolyte compatibility, and appropriate cut-off voltages to avoid accelerated degradation. Always use appropriate PPE, glovebox or dry-room practices when needed, and follow your lab’s chemical handling procedures for powders and solvents.

CLOSING SUMMARY

Sodium-ion battery materials enable rigorous, research-grade evaluation of Na-ion cell performance—from hard-carbon anodes to layered oxides, Prussian analogues, and phosphate cathodes. By selecting the right chemistry, PSD, and handling approach, you can generate repeatable datasets that translate from screening to prototype development. ScienceGears supports researchers across Australia and New Zealand with selection guidance and practical testing workflows.