Electrode fabrication methods and associated systems and articles

Patent metadata

Field	Value
Publication number	US-10319988-B2
Application number	US-201715623604-A
Country	US
Kind code	B2
Filing date	Jun 15, 2017
Priority date	May 1, 2014
Publication date	Jun 11, 2019
Grant date	Jun 11, 2019

Abstract

Sulfur-based electrodes, and associated systems and methods for their fabrication, are generally described. Certain embodiments relate to sulfur-based electrodes with smooth external surfaces. According to some embodiments, relatively large forces can be applied to compositions from which the sulfur-based electrodes are made during the fabrication process. In some such embodiments, the compositions can maintain relatively high porosities, even after the relatively large forces have been applied to them. Methods in which liquids are employed during the electrode fabrication process are also described.

First claim

What is claimed is:

1. An electrode, comprising:
an external geometric active surface comprising:
a particulate electronically conductive material;
an electrode active material; and
a binder;
wherein:
the electrode has a porosity of at least about 40%, and
the external geometric active surface of the electrode has a root mean square surface roughness of at least about 0.1 micrometers and less than or equal to about 15 micrometers over a geometric surface area of at least about 10,000 square micrometers.

2. The electrode of claim 1 , wherein the particulate electronically conductive material is porous.

3. The electrode of claim 1 , wherein the particulate electronically conductive material comprises carbon.

4. The electrode of claim 3 , wherein the particulate electronically conductive material comprises carbon black.

5. The electrode of claim 1 , wherein the particulate electronically conductive material has a bulk electronic resistivity of less than about 10 −3 ohm-m at 20° C.

6. The electrode of claim 1 , wherein the electrode active material comprises sulfur.

7. The electrode of claim 6 , wherein the electrode active material comprises elemental sulfur.

8. The electrode of claim 1 , wherein the binder comprises a polymeric binder.

9. The electrode of claim 8 , wherein the binder comprises polyvinyl alcohol.

10. The electrode of claim 1 , wherein the electrode has a porosity of at least about 40% and up to about 70%.

11. The electrode of claim 1 , wherein the thickness of the electrode is less than or equal to about 1 mm.

12. The electrode of claim 11 , wherein the thickness of the electrode is at least about 10 micrometers and less than or equal to about 1 mm.

13. An electrochemical cell comprising the electrode of claim 1 .

14. The electrochemical cell of claim 13 , comprising a second electrode comprising lithium.

15. The electrochemical cell of claim 14 , wherein the second electrode comprises lithium metal and/or a lithium alloy.

Assignees

• Sion Power Corp

Inventors

• Kelley Tracy Earl
• Burnside-Joubert Savannah V
• Schmidt Ruediger
• Schneider Holger
• Leitner Klaus
• Kulisch Joern

Classifications

• H01M4/0404 Primary

  by coating on electrode collectors · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M10/052

  Li-accumulators · CPC title

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M4/622

  being polymers · CPC title