CN110679008B

CN110679008B - Shape conforming alkali metal-sulfur battery

Info

Publication number: CN110679008B
Application number: CN201880035240.1A
Authority: CN
Inventors: 阿茹娜·扎姆; 张博增
Original assignee: Nanotek Instruments Inc
Current assignee: Nanotek Instruments Inc
Priority date: 2017-06-02
Filing date: 2018-05-08
Publication date: 2022-09-20
Anticipated expiration: 2038-05-08
Also published as: CN110679008A; JP2020523733A; WO2018222349A1; KR20200014325A

Abstract

An alkali-sulfur cell is provided, the alkali-sulfur cell comprising: (a) a quasi-solid cathode comprising from about 30% to about 95% by volume of a cathode active material (sulfur-containing material), from about 5% to about 40% by volume of a first electrolyte comprising an alkali metal salt dissolved in a solvent and an ionically conductive polymer dissolved, dispersed, or impregnated by the solvent, and from about 0.01% to about 30% by volume of a conductive additive, wherein the conductive additive comprising conductive filaments forms a 3D network of electron conducting pathways, such that the quasi-solid electrode has from about 10 ^‑6 A conductivity of S/cm to about 300S/cm; (b) an anode; and (c) an ion-conducting membrane or porous separator disposed between the anode and the quasi-solid cathode; wherein the quasi-solid cathode has a thickness of from 200 μm to 100cm and has a thickness of greater than 10mg/cm ² Active material mass loading of cathode active material.

Description

Shape conforming alkali metal-sulfur battery

Cross Reference to Related Applications

This application claims priority from us patent application No. 15/612,497 filed on day 6/2 2017 and us patent application No. 15/612,537 filed on day 6/2 2017, which are incorporated herein by reference.

Technical Field

The present invention relates generally to the field of alkali metal-sulfur batteries, including rechargeable lithium metal-sulfur batteries, sodium metal-sulfur batteries, lithium ion-sulfur batteries, and sodium ion-sulfur batteries.

Background

Rechargeable lithium-ion (Li-ion) and lithium metal batteries, including Li-sulfur and Li metal-air batteries, are considered promising power sources for Electric Vehicles (EVs), Hybrid Electric Vehicles (HEVs), and portable electronic devices, such as laptop computers and cell phones. With any other metal or metal intercalation compound (except Li having a specific capacity of 4,200 mAh/g) as an anode active material _4.4 Si) has the highest capacity (3,861mAh/g) compared to lithium as the metal element. Therefore, in general, Li metal batteries have a significantly higher energy density than lithium ion batteries.

Historically, rechargeable lithium metal batteries have used non-lithiated compounds such as TiS that have a relatively high specific capacity ₂ 、MoS ₂ 、MnO ₂ 、CoO ₂ And V ₂ O ₅ Produced as cathode active materials, these cathode active materials are coupled to lithium metal anodes. When the battery is discharged, lithium ions are transferred from the lithium metal anode to the cathode through the electrolyte, and the cathode becomes lithiated. Unfortunately, upon repeated charge/discharge, lithium metal causes dendrites to form at the anode, and theseThe dendrites eventually grow to penetrate the membrane, causing internal short circuits and explosions. Due to a series of accidents related to this problem, the production of these types of secondary batteries was stopped in the early nineties of the twentieth century, and lithium ion batteries were replaced.

In lithium ion batteries, carbonaceous materials replace pure lithium metal sheets or membranes as anodes. The carbonaceous material absorbs lithium (e.g., by intercalation of lithium ions or atoms between graphene planes) and desorbs lithium ions during the recharge and discharge phases, respectively, of the lithium ion battery operation. The carbonaceous material may include primarily graphite that may be intercalated with lithium, and the resulting graphite intercalation compound may be represented as Li _x C ₆ Where x is typically less than 1.

While lithium-ion (Li-ion) batteries are promising energy storage devices for electrically driven vehicles, today's state-of-the-art Li-ion batteries have not met cost and performance goals. Li ion cells typically use lithium transition metal oxides or phosphates as the deintercalating/re-intercalating Li at high potentials relative to a carbon negative electrode (anode) ⁺ Positive electrode (cathode). The specific capacity of lithium transition metal oxide or phosphate based cathode active materials is typically in the range of from 140-170 mAh/g. As a result, the specific energy of commercially available Li ion cells is typically in the range from 120-250Wh/kg, most typically in the range of 150-220 Wh/kg. These specific energy values are two to three times lower than those required for widespread acceptance of battery-powered electric vehicles.

With the rapid development of Hybrid Electric Vehicles (HEVs), plug-in Hybrid Electric Vehicles (HEVs), and all-battery Electric Vehicles (EVs), there is an urgent need to provide anode and cathode materials for rechargeable batteries with significantly higher specific energy, higher energy density, higher rate performance, long cycle life, and safety. One of the most promising energy storage devices is a lithium-sulfur (Li-S) cell, since the theoretical capacity of Li is 3,861mAh/g and the theoretical capacity of S is 1,675 mAh/g. In its simplest form, a Li-S cell consists of elemental sulfur as the positive electrode and lithium as the negative electrode. The lithium-sulfur cell is operated with a redox couple by reaction

Described, the reaction is relative to Li ⁺ /Li ^o Located near 2.2V. This electrochemical potential is that of a conventional positive electrode in a conventional lithium ion battery (e.g., LiMnO) ₄ ) About 2/3 for the electrochemical potential shown. However, this disadvantage is offset by the very high theoretical capacities of both Li and S. Thus, Li-S cells have the opportunity to provide significantly higher energy density (the product of capacitance and voltage) than conventional intercalation-based Li-ion batteries. Assuming complete reaction to Li ₂ S, energy density values can approach 2,500Wh/kg and 2,800Wh/L, respectively, based on combined Li and S weight or volume. Energy densities can reach approximately 1,000Wh/kg and 1,100Wh/L, respectively, if based on total cell weight or volume. However, current Li-sulfur cells reported by industry leaders of sulfur cathode technology have maximum cell specific energies of 250-400Wh/kg and 500-650Wh/L (based on total cell weight or volume), which are far below the possible specific energies.

In summary, despite its considerable advantages, Li-S cells suffer from several major technical problems which, to date, have prevented their widespread commercialization:

(1) conventional lithium metal cells still have dendrite formation and associated internal short circuit problems.

(2) Sulfur or sulfur-containing organic compounds are highly insulating in both electrical and ionic respects. In order to achieve a reversible electrochemical reaction at high current densities or charge/discharge rates, the sulfur must remain in intimate contact with the conductive additive. Various carbon-sulfur composites have been used for this purpose, but with limited success due to the limited scale of the contact area. Typical reported capacities are between 300 and 550mAh/g at moderate rates (based on cathode carbon-sulfur composite weight).

(3) Cells tend to exhibit significant capacity fade during discharge-charge cycles. This is mainly due to the high solubility of lithium polysulfide anions formed as reaction intermediates during both discharge and charge processes in the polar organic solvents used for the electrolyte. During the circulation, polysulfidesLithium-iodide anions can migrate through the separator to the Li negative electrode, whereupon they are reduced to solid precipitates (Li) ₂ S ₂ And/or Li ₂ S), causing a loss of active mass. Furthermore, the solid products precipitated on the surface of the positive electrode during discharge become electrochemically irreversible, which also contributes to the loss of active mass.

(4) More generally, a significant drawback of cells containing cathodes comprising elemental sulfur, organosulfur and carbon-sulfur materials relates to the dissolution of soluble sulfides, polysulfides, organosulfides, carbon-sulfides and/or carbon-polysulfides (hereinafter referred to as anionic reduction products) and excessive out-diffusion from the cathode into the rest of the cell. This phenomenon is commonly referred to as the shuttling effect. This process leads to several problems: high self-discharge rates, loss of cathode capacity, corrosion of current collectors and electrical leads leading leads to loss of electrical contact with active cell components, fouling of the anode surface leads to anode failure, and pore plugging in cell membrane separators leads to ion transport losses and a large increase in internal resistance in the cell.

In response to these challenges, new electrolytes, protective films for lithium anodes, and solid electrolytes have been developed. Recently some interesting cathode developments were reported containing lithium polysulphides; however, their performance still does not meet the requirements of practical application.

For example, Ji et al report that nanostructured sulfur/mesoporous carbon material based cathodes can largely overcome these challenges and exhibit stable, high, reversible capacity with good rate characteristics and cycling efficiency [ Xiulei Ji, Kyu Tae Lee, & Linda f. nanozar, "a high ordered nanostructured carbon-sulfur cathode for lithium-sulfur batteries ]," Nature Materials [ natural Materials ]8, 500-. However, the proposed fabrication of highly ordered mesoporous carbon structures requires a lengthy and expensive template-assisted process. It is also challenging to load a large proportion of sulfur into these mesoscale pores using physical vapor deposition or solution precipitation methods.

Zhang et al (U.S. publication)Number 2014/0234702; 08/21/2014) utilize a chemical reaction process that deposits S particles on the surface of isolated Graphene Oxide (GO) sheets. However, this approach does not produce a large proportion of S particles on the GO surface (i.e., typically S in GO-S nanocomposite compositions)<66%). The obtained Li-S cell also exhibits poor rate performance; for example, the specific capacity of 1,100mAh/g (based on S weight) at 0.02C rate is reduced to 1.0C rate<450 mAh/g. It can be noted that the highest achievable specific capacity of 1,100mAh/g represents a sulfur utilization efficiency of only 1,100/1,675 ═ 65.7% even at such low charge/discharge rates (0.02C means that the charging or discharging process is completed within 50 hours of 1/0.02 ═ 1 hour, 2C ═ 1 hour ¹ / ₂ Hour, and 3C 1/3 hour, etc.). Furthermore, such S-GO nanocomposite cathode-based Li-S cells exhibit very poor cycle life, with capacity typically decreasing to less than 60% of its initial capacity in less than 40 charge/discharge cycles. This short cycle life makes this Li-S cell unusable for any practical application. Another chemical reaction method for depositing S particles on the surface of graphene oxide is disclosed by Wang et al (U.S. publication No. 2013/0171339; 07/04/2013). Such Li-S cells still suffer from the same problems.

Liu et al (U.S. publication No. 2012/0088154; 04/12/2012) disclose a solution precipitation process for preparing graphene-sulfur nanocomposites (with sulfur particles adsorbed on the GO surface) for use as cathode materials in Li-S cells. The method requires the presence of a solvent (CS) ₂ ) Wherein GO sheets and S are mixed to form a suspension. The solvent is then evaporated to produce a solid nanocomposite which is then milled to produce a nanocomposite powder having primary sulfur particles with an average diameter of less than about 50 nm. Unfortunately, this method does not appear to produce S particles smaller than 40 nm. The resulting Li-S cells exhibited very poor cycle life (50% capacity fade after only 50 cycles). Even when these nanocomposite particles are encapsulated in a polymer, the Li-S cell remains less than 80% of its initial capacity after 100 cycles. The cells also exhibit poor rate performance (specific capacity of 1,050mAh/g (S weight) at 0.1C rate) atReduced to 1.0C rate<580 mAh/g). Again, this suggests that a large proportion of S does not contribute to lithium storage, resulting in low S utilization efficiency.

Despite the various methods proposed for fabricating high energy density Li-S cells, there remains a need for cathode materials and production methods that improve the utilization of electroactive cathode materials (S utilization efficiency) and provide rechargeable Li-S cells with high capacity over many cycles.

Most importantly, lithium metal (including pure lithium, lithium alloys with other metallic elements having high lithium content, or lithium-containing compounds having high lithium content; e.g. > 80% or preferably > 90% by weight Li) still provides the highest specific anode capacity compared to essentially all other anode active materials (except pure silicon, but silicon has pulverization problems). Lithium metal would be an ideal anode material in lithium-sulfur secondary batteries if dendrite related problems could be solved.

Sodium metal (Na) and potassium metal (K) have similar chemical characteristics as Li and sulfur cathodes in room temperature sodium-sulfur cells (RT Na-S batteries) or potassium-sulfur cells (K-S) face the same problems observed in Li-S batteries, such as: (i) low active material utilization, (ii) poor cycle life, and (iii) low coulombic efficiency. Again, these disadvantages are mainly caused by the insulating properties of S, the dissolution of S and sodium or potassium polysulfide intermediates in the liquid electrolyte (and the associated shuttle effects), and the large volume change during charge/discharge.

It may be noted that in most published literature reports (scientific papers) and patent literature, scientists or inventors chose to express the cathode specific capacity based on the weight of sulfur or lithium polysulfide alone (rather than the total cathode composite weight), but unfortunately, a large proportion of inactive materials (those that cannot store lithium, such as conductive additives and binders) are typically used in their Li-S cells. For practical purposes, it is more meaningful to use a capacity value based on the weight of the cathode composite.

Low capacity anode or cathode active materials are not the only problems associated with lithium-sulfur or sodium-sulfur batteries. The existence of battery industry seems to be unrecognized or in great measureSerious design and manufacturing problems are largely ignored. For example, despite seemingly high weight capacity at the electrode level (based on the weight of the anode or cathode active material alone) as often required in the publications and patent documents, these electrodes unfortunately cannot provide batteries with high capacity at the battery cell or battery pack level (based on the total battery cell weight or battery pack weight). This is due to the following view: in these reports, the actual active material mass loading of the electrode was too low. In most cases, the mass loading (areal density) of active material of the anode is significantly below 15mg/cm ² And most are<8mg/cm ² (areal density is the amount of active material per electrode cross-sectional area along the thickness of the electrode). The amount of cathode active material in the cell is typically 1.5 to 2.5 times higher than the amount of anode active material. As a result, the weight proportion of anode active material (e.g., carbon) in a Na ion-sulfur or Li ion-sulfur battery cell is typically from 15% to 20%, and the weight proportion of cathode active material is from 20% to 35% (most of the weight proportions of the cathode active material are from 15% to 20%)<30%). The weight fraction of the combined cathode active material and anode active material is typically from 35% to 50% of the cell weight.

The low active material mass loading was mainly due to the inability to obtain thicker electrodes (thicker than 100-200 μm) using conventional slurry coating procedures. This is not a trivial task as one might think, and for the purpose of optimizing cell performance, electrode thickness is not a design parameter that can be varied arbitrarily and freely. Conversely, thicker samples tend to become extremely brittle or have poor structural integrity, and will also require the use of large amounts of binder resin. Due to the low melting point and soft character of sulfur, it is practically impossible to produce sulfur cathodes thicker than 100 μm. Furthermore, in an actual battery manufacturing plant, coated electrodes thicker than 150 μm would require heating zones up to 100 meters long to thoroughly dry the coated slurry. This will significantly increase equipment costs and reduce production throughput. The low areal and volumetric densities (associated with thin electrodes and poor packing densities) result in relatively low volumetric capacity and low volumetric energy density of the battery cells.

With the increasing demand for more compact and portable energy storage systems, there is a strong interest in increasing the utilization of the volume of the battery. Novel electrode materials and designs that enable high volumetric capacity and high mass loading are critical to achieving improved cell volumetric capacity and energy density.

It is therefore an object of the present invention to provide a rechargeable alkali metal-sulfur cell based on rational materials and battery design that overcomes or significantly reduces the following problems typically associated with conventional Li-S and Na-S cells: (a) dendrite formation (internal short circuit); (b) extremely low electrical and ionic conductivity of sulfur, requiring a large proportion (typically 30% -55%) of inactive conductive filler and having a significant proportion of inaccessible or inaccessible sulfur or alkali metal polysulfides); (c) the dissolution of S and alkali metal polysulfides in the electrolyte and the migration of polysulfides from the cathode to the anode (where they react irreversibly with Li or Na metal), leading to active material loss and capacity fade (shuttle effect); (d) short cycle life; and (e) low active mass loading in both the anode and cathode.

It is a particular object of the present invention to provide a rechargeable alkali metal-sulfur battery (e.g., primarily Li-S and room temperature Na-S batteries) that exhibits exceptionally high specific energy or high energy density. It is a particular technical object of the present invention to provide an alkali metal-sulfur or alkali metal ion-sulfur cell having a cell specific energy of greater than 400Wh/Kg, preferably greater than 500Wh/Kg, more preferably greater than 600Wh/Kg, and most preferably greater than 700Wh/Kg (all based on total cell weight). Preferably, the volumetric energy density is greater than 600Wh/L, further preferably greater than 800Wh/L, and most preferably greater than 1,000 Wh/L.

It is another object of the invention to provide an alkali metal-sulfur cell that exhibits a high cathode specific capacity (greater than 1,200mAh/g based on sulfur weight, or greater than 1,000mAh/g based on cathode composite weight (including combined sulfur, conductive additive or substrate, and binder weight, but not including the weight of the cathode current collector)). The specific capacity is preferably greater than 1,400mAh/g based on sulfur alone or greater than 1,200mAh/g based on the weight of the cathode composite. This must be accompanied by high specific energy, good resistance to dendrite formation, and long and stable cycle life.

As electronic devices become more compact and Electric Vehicles (EVs) become lighter in weight, there is a pressing need for high energy density batteries that are shape conformable so that they can fit into some odd shape or confined space in the device or vehicle. By implementing the battery in a space (e.g., a portion of a vehicle door or roof) that would otherwise be empty (unused or "wasted") space, the device may be made more compact or the EV may be enabled to store more power. In order for the battery to be shape conformable, the electrodes must be deformable, flexible, and shape conformable.

Thus, there is a clear and urgent need for lithium and sodium batteries with high active material mass loading (high areal density), high electrode thickness or volume without compromising conductivity, high rate capability, high power density, and high energy density. These batteries must be produced in an environmentally friendly manner. In addition, the battery must be shape conformable.

Disclosure of Invention

The present invention provides a method of producing a flexible and shape-conforming lithium-sulfur or sodium-sulfur battery having high active material mass loading, exceptionally low overhead weight and volume (relative to active material mass and volume), high capacity, and unprecedented high energy and power densities. The Li-S or Na-S battery may be a primary (non-rechargeable) or secondary (rechargeable) battery, including rechargeable lithium metal-sulfur or sodium metal-sulfur batteries (having a lithium or sodium metal anode) and lithium ion-sulfur or sodium ion-sulfur batteries (e.g., having a first lithium intercalation compound as the anode active material).

In certain embodiments, the present disclosure provides an alkali metal-sulfur cell comprising: (a) a quasi-solid cathode comprising from about 30% to about 95% by volume of a sulfur-containing cathode active material (preferably selected from sulfur, metal-sulfur compounds, sulfur-carbon composites, sulfur-graphene composites, sulfur-graphite composites, organosulfur compounds, sulfur-polymer composites, or a group thereofClose), about 5% to about 40% by volume of a first electrolyte comprising an alkali metal salt dissolved in a solvent and an ionically conductive polymer dissolved in, dispersed in, or impregnated by the solvent, and about 0.01% to about 30% by volume of a conductive additive, wherein the conductive additive comprising conductive filaments forms a 3D network of electron conducting pathways, thereby providing the quasi-solid electrode with from about 10 ^-6 A conductivity of S/cm to about 300S/cm; (b) an anode; and (c) an ion-conducting membrane or porous separator disposed between the anode and the quasi-solid cathode; wherein the quasi-solid cathode has a thickness of not less than 200 μm. The quasi-solid cathode preferably contains not less than 10mg/cm ² Preferably not less than 15mg/cm ² Further preferably not less than 25mg/cm ² More preferably not less than 35mg/cm ² Still more preferably not less than 45mg/cm ² And most preferably greater than 65mg/cm ² Mass loading of cathode active material.

In the cell, the anode may comprise a quasi-solid anode comprising about 1.0% to about 95% by volume of an anode active material, about 5% to about 40% by volume of a second electrolyte comprising an alkali metal salt dissolved in a solvent and an ionically conductive polymer dissolved, dispersed, or impregnated with the solvent, and about 0.01% to about 30% by volume of a conductive additive, wherein the conductive additive comprising electrically conductive filaments forms a 3D network of electron conducting pathways, such that the quasi-solid electrode has from about 10 ^-6 A conductivity of S/cm to about 300S/cm; wherein the quasi-solid anode has a thickness of not less than 200 μm. The quasi-solid anode preferably contains not less than 10mg/cm ² Preferably not less than 15mg/cm ² Further preferably not less than 25mg/cm ² More preferably not less than 35mg/cm ² Still more preferably not less than 45mg/cm ² And most preferably greater than 65mg/cm ² Mass loading of anode active material. The composition and structure of the first electrolyte may be the same as or different from the second electrolyte.

In certain embodiments, the present invention provides an alkali metal-sulfur cell,the alkali-sulfur cell comprises: (A) a quasi-solid anode comprising from about 1.0% to about 95% by volume of an anode active material, from about 5% to about 40% by volume of an electrolyte comprising an alkali metal salt dissolved in a solvent and an ionically conductive polymer dissolved, dispersed, or impregnated with the solvent, and from about 0.01% to about 30% by volume of a conductive additive, wherein the conductive additive comprising electrically conductive filaments forms a 3D network of electron conducting pathways, such that the quasi-solid anode has from about 10 ^-6 A conductivity of S/cm to about 300S/cm; (B) a cathode comprising a sulfur-containing cathode active material selected from the group consisting of: sulfur, metal-sulfur compounds, sulfur-carbon composites, sulfur-graphene composites, sulfur-graphite composites, organosulfur compounds, sulfur-polymer composites, or combinations thereof; and (C) an ion conducting membrane or porous separator disposed between the quasi-solid anode and the cathode; wherein the quasi-solid anode and the cathode preferably each have a thickness of not less than 200 μm.

The quasi-solid polymer electrodes of the present invention are deformable, flexible, and shape-conformable, thereby enabling shape-conformable batteries.

The invention also provides a method of making an alkali metal-sulfur cell with a quasi-solid electrode, the method comprising: (a) combining an amount of active material (anode active material or cathode active material), an amount of electrolyte comprising an alkali metal salt dissolved in a solvent and an ionically conductive polymer dissolved, dispersed, or impregnated by the solvent, and a conductive additive to form a deformable and conductive electrode material, wherein the conductive additive comprising conductive filaments forms a 3D network of electron conducting pathways; (b) forming the electrode material as a quasi-solid electrode, wherein the forming step comprises deforming the electrode material into an electrode shape without interrupting the 3D network of electron conduction pathways, thereby causing the electrode to remain no less than 10 ^-6 S/cm (preferably not less than 10) ^-5 S/cm, more preferably not less than 10 ^-3 S/cm, further preferably not less than 10 ^-2 S/cm, still more preferably and typically not less than 10 ^-1 S/cm, even more typically and preferably not less than 1S/cm, and further more typically and preferably not less than 10S/cm and up to 300S/cm); (c) forming a second electrode (the second electrode may also be a quasi-solid electrode); and (d) forming an alkali metal-sulfur cell by combining the quasi-solid electrode and the second electrode, the alkali metal-sulfur cell having an ion-conducting separator disposed between the two electrodes.

In some embodiments, the electrolyte (including the first electrolyte or the second electrolyte) contains a lithium ion conducting polymer or a sodium ion conducting polymer selected from the group consisting of: poly (ethylene oxide) (PEO, with less than 1x10 ⁶ g/mol, preferably less than 0.5X 10 ⁶ Molecular weight in g/mol), polypropylene oxide (PPO), poly (acrylonitrile) (PAN), poly (methyl methacrylate) (PMMA), poly (vinylidene fluoride) (PVDF), poly bis (methoxyethoxyethanol-phosphazene), polyvinyl chloride, polydimethylsiloxane, poly (vinylidene fluoride) -hexafluoropropylene (PVDF-HFP), sulfonated derivatives thereof, sulfonated polymers, or combinations thereof. It is found herein that sulfonation imparts improved lithium ion conductivity to the polymer. Higher than 1x10 ⁶ The g/mol PEO molecular weight typically renders the PEO insoluble and non-dispersible in the solvent.

Typically and preferably, the ion-conducting polymer does not form a matrix (continuous phase) in the electrode.

The ion conducting polymer may be selected from the group consisting of: poly (perfluorosulfonic acid), sulfonated polytetrafluoroethylene, sulfonated perfluoroalkoxy derivatives of polytetrafluoroethylene, sulfonated polysulfone, sulfonated poly (ether ketone), sulfonated poly (ether ketone), sulfonated polystyrene, sulfonated polyimide, sulfonated styrene-butadiene copolymers, sulfonated Polychlorotrifluoroethylene (PCTFE), sulfonated perfluoroethylene-propylene copolymers (FEP), sulfonated ethylene-chlorotrifluoroethylene copolymers (ECTFE), sulfonated polyvinylidene fluoride (PVDF), sulfonated copolymers of polyvinylidene fluoride with hexafluoropropylene and tetrafluoroethylene, sulfonated copolymers of Ethylene and Tetrafluoroethylene (ETFE), sulfonated Polybenzimidazole (PBI), chemical derivatives, copolymers, blends, and combinations thereof. We have surprisingly found that these sulfonated polymers are lithium ion conductive and sodium ion conductive.

A "filament" is an object of solid material having a largest dimension (e.g. length) and a smallest dimension (e.g. diameter or thickness) and a ratio of largest dimension to smallest dimension of greater than 3, preferably greater than 10, and further preferably greater than 100. Typically, the filaments are, by way of example only, linear, fibrous, needle-like, rod-like, platelet-like, sheet-like, ribbon-like, or disk-like objects. In certain embodiments, the conductive filament is selected from a carbon fiber, a graphite fiber, a carbon nanofiber, a graphite nanofiber, a carbon nanotube, an acicular coke, a carbon whisker, a conductive polymer fiber, a conductive material coated fiber, a metal nanowire, a metal fiber, a metal wire, a graphene sheet, an expanded graphite platelet, combinations thereof, or combinations thereof with non-filament conductive particles.

In certain embodiments, the electrode is maintained from 10 ^-5 A conductivity of S/cm to about 100S/cm.

In certain embodiments, the deformable electrode material has a thickness of 1,000s ^-1 An apparent viscosity of not less than about 10,000Pa-s, measured at an apparent shear rate. In certain embodiments, the deformable electrode material has a thickness of 1,000s ^-1 Is not less than about 100,000Pa-s at an apparent shear rate.

In the method, the amount of active material typically comprises from about 20% to about 95% by volume of the electrode material, more typically from about 35% to about 85% by volume of the electrode material, and most typically from about 50% to about 75% by volume of the electrode material.

Preferably, the step of combining the active material, the conductive additive, and the electrolyte (including dissolving the lithium or sodium salt in the liquid solvent) follows a specific sequence. This step includes first dispersing the conductive filaments in a liquid solvent to form a homogeneous suspension, then adding the active material in the suspension and then dissolving a lithium or sodium salt in the liquid solvent and then dissolving or dispersing the ionically conductive polymer in the solvent. In other words, the conductive filaments must first be uniformly dispersed in the liquid solvent before adding other ingredients, such as active materials and ion-conducting polymers, and before dissolving lithium or sodium salts in the solvent. This sequence is crucial for achieving percolation of the conductive filaments in order to form a 3D network of electron conducting pathways at a lower volume fraction of the conductive filaments (lower threshold volume fraction). Without following this sequence, percolation of the conductive filaments may not occur or only occur upon addition of an excessively large proportion of conductive filaments (e.g., > 10% by volume), which would reduce the fraction of active material and thus the energy density of the cell.

In certain embodiments, the step of combining and forming the electrode material into a quasi-solid electrode comprises dissolving a lithium salt (or sodium salt) and an ion conducting polymer in a liquid solvent to form a polymer electrolyte having a first salt concentration and a first polymer concentration and then removing a portion of the liquid solvent to increase the salt concentration to obtain a quasi-solid polymer electrolyte having a second salt concentration and a second polymer concentration, the second concentration being higher than the first concentration and preferably higher than 2.5M (and more preferably from 3.0M to 14M) of a salt and polymer combination. The resulting electrolyte is in a supersaturated state without precipitation or crystallization of salts and/or polymers from the electrolyte.

The step of removing a portion of the solvent may be performed in a manner that does not cause precipitation or crystallization of the salt and the polymer and the electrolyte is in a supersaturated state. In certain preferred embodiments, the liquid solvent comprises a mixture of at least a first liquid solvent and a second liquid solvent and the first liquid solvent is more volatile than the second liquid solvent, wherein the step of removing a portion of the liquid solvent comprises partially or completely removing the first liquid solvent. The resulting electrolyte is in a supersaturated state without precipitation or crystallization of salts and/or polymers from the electrolyte.

There is no limitation on the type of anode active material that can be used to practice the present invention. In certain preferred embodiments, the alkali metal cell is a lithium metal battery, a lithium ion battery, or a lithium ion capacitor, wherein the anode active material is selected from the group consisting of: (a) particles of lithium metal or lithium metal alloy; (b) natural graphite particles, artificial graphite particles, mesocarbon microbeads (MCMB), carbon particles (including soft and hard carbon), needle coke, carbon nanotubes, carbon nanofibers, carbon fibers, and graphite fibers; (c) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), nickel (Ni), cobalt (Co), manganese (Mn), titanium (Ti), iron (Fe), and cadmium (Cd); (d) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al or Cd with other elements, wherein the alloys or compounds are stoichiometric or non-stoichiometric; (e) oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ni, Co, Ti, Mn, or Cd, and mixtures or composites thereof; (f) a prelithiated version thereof; (g) pre-lithiated graphene sheets; and combinations thereof.

In certain embodiments, the alkali metal-sulfur cell is a sodium metal-sulfur cell or a sodium ion-sulfur cell and the active material is an anode active material comprising a sodium intercalation compound selected from: petroleum coke, amorphous carbon, activated carbon, hard carbon (hard graphitizable carbon), soft carbon (graphitizable carbon), template carbon, hollow carbon nanowire, hollow carbon sphere, titanate, NaTi ₂ (PO ₄ ) ₃ 、Na ₂ Ti ₃ O ₇ 、Na ₂ C ₈ H ₄ O ₄ 、Na ₂ TP、Na _x TiO ₂ (x ═ 0.2 to 1.0), Na ₂ C ₈ H ₄ O ₄ Materials based on carboxylic acid salts, C ₈ H ₄ Na ₂ O ₄ 、C ₈ H ₆ O ₄ 、C ₈ H ₅ NaO ₄ 、C ₈ Na ₂ F ₄ O ₄ 、C ₁₀ H ₂ Na ₄ O ₈ 、C ₁₄ H ₄ O ₆ 、C ₁₄ H ₄ Na ₄ O ₈ Or a combination thereof.

In certain embodiments, the alkali metal-sulfur cell is a sodium metal-sulfur cell or a sodium ion-sulfur cell and the active material is an anode active material selected from the group consisting of: (a) particles of sodium metal or sodium metal alloy; (b) natural graphite particles, artificial graphite particles, Mesophase Carbon Microspheres (MCMB), carbon particles, needle coke, carbon nanotubes, carbon nanofibers, carbon fibers, and graphite fibers; (c) sodium-doped silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), cobalt (Co), nickel (Ni), manganese (Mn), cadmium (Cd), and mixtures thereof; (d) sodium-containing alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Co, Ni, Mn, Cd, and mixtures thereof; (e) sodium-containing oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides, or antimonides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ti, Co, Ni, Mn, Cd, and mixtures or composites thereof; (f) a sodium salt; and (g) graphene sheets pre-loaded with sodium ions; and combinations thereof.

The electrolyte may contain water, an organic liquid, an ionic liquid (an ionic salt having a melting temperature below 100 ℃, preferably below 25 ℃ at room temperature), or a mixture of an ionic liquid and an organic liquid in a ratio of from 1/100 to 100/1. Organic liquids are desirable, but ionic liquids are preferred. The electrolyte typically and preferably contains a high solute concentration (combined concentration of lithium/sodium salt and polymer) that places the solute in a saturated or supersaturated state in the resulting electrode (anode or cathode). Such electrolytes are essentially polymer electrolytes that behave like deformable or conformable solids. This is fundamentally different from a liquid electrolyte or a polymer gel electrolyte.

In a preferred embodiment, the quasi-solid electrode has a thickness of from 200 μm to 1cm, preferably from 300 μm to 0.5cm (5mm), further preferably from 400 μm to 3mm, and most preferably from 500 μm to 2.5mm (2,500 μm). If the active material is an anode active material, the anode active material has not less than 25mg/cm ² (preferably not less than 30 mg/cm) ² And more preferably not less than 35mg/cm ² ) And/or at least 25% (preferably at least 30% and more preferably at least 35%) by weight or by volume of the entire battery cell). If the active material is a cathode active material, the cathode active material preferably has not less than 20mg/cm in the cathode ² (preferably not less than 25 mg/cm) ² And more preferably not less than 30mg/cm ² Most preferably not less than 40mg/cm ² ) And/or at least 45% (preferably at least 50% and more preferably at least 55%) by weight or by volume of the entire battery cell.

The above requirements for electrode thickness, anode active material areal mass loading or mass fraction relative to the overall battery cell, or cathode active material areal mass loading or mass fraction relative to the overall battery cell are not possible in the case of conventional lithium or sodium batteries using conventional slurry coating and drying processes.

In some embodiments, the anode active material is a prelithiated version of a graphene sheet selected from pristine graphene, graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, boron-doped graphene, nitrogen-doped graphene, chemically functionalized graphene, a physically or chemically activated or etched version thereof, or a combination thereof. Surprisingly, the resulting lithium battery cells do not exhibit satisfactory cycle life (i.e., rapid capacity fade) without prelithiation.

In the lithium metal battery, the cathode active material composition is greater than 15mg/cm ² (preferably greater than 25 mg/cm) ² More preferably more than 35mg/cm ² And most preferably greater than 50mg/cm ² ) And/or wherein the electrode has a thickness of not less than 300 μm (preferably not less than 400 μm, more preferably not less than 500 μm, and may be up to or greater than 100 cm). There is no theoretical limit to the thickness of the electrode of the alkali metal battery of the present invention.

Drawings

Fig. 1(a) a schematic of a prior art lithium ion battery cell comprised of an anode current collector, one or two layers of anode active material (e.g., thin Si coating) coated on both major surfaces of the anode current collector, a porous separator and electrolyte, one or two layers of cathode electrode (e.g., sulfur layer), and a cathode current collector;

FIG. 1(B) schematic of a prior art lithium ion battery in which the electrode layers are made of active materials (e.g., graphite or tin oxide particles in the anode layer or LiCoO in the cathode layer) ₂ ) Of the conductive additive (not shown), and a resin binder (not shown).

Fig. 1(C) is a schematic of a lithium ion battery cell of the present invention comprising a quasi-solid anode (consisting of anode active material particles and conductive filaments mixed or dispersed directly in an electrolyte), a porous separator, and a quasi-solid cathode (consisting of cathode active material particles and conductive filaments mixed or dispersed directly in an electrolyte). In this embodiment, no resin binder is required.

Fig. 1(D) is a schematic of a lithium metal battery cell of the invention comprising an anode (comprising a lithium metal layer deposited on the surface of a Cu foil), a porous separator, and a quasi-solid cathode (consisting of particles of a cathode active material and conductive filaments mixed or dispersed directly in an electrolyte). In this embodiment, no resin binder is required.

FIG. 2(A) a schematic of a close-packed highly ordered structure of a solid electrolyte;

FIG. 2(B) has a cation (e.g., Na) ⁺ ) A schematic illustration of a fully amorphous liquid electrolyte with a large free volume portion that can easily migrate through;

fig. 2(C) has a random or amorphous structure of a quasi-solid electrolyte with solvent molecules separating salt species to create amorphous regions that facilitate migration of free (unclustered) cations. The ion-conducting polymer is also in a supersaturated state, which is still substantially amorphous.

FIG. 3(A) Na of electrolyte (e.g. (PEO + NaTFSI salt) in (DOL + DME) solvent) related to sodium salt molecular ratio x ⁺ Ion transfer number.

FIG. 3(B) Na of electrolyte (e.g. (PPO + NaTFSI salt) in (EMImTFSI + DOL) solvent) related to sodium salt molecular ratio x ⁺ Ion transfer number.

Figure 4 is a schematic of a common process for producing expanded graphite, expanded graphite flakes (thickness >100nm) and graphene sheets (thickness <100nm, more typically <10nm, and can be as thin as 0.34 nm).

Fig. 5(a) conductivity (percolation behavior) of conductive filaments in a quasi-solid polymer electrode plotted as a function of volume fraction of conductive filaments (carbon nanofibers).

Fig. 5(B) conductivity (percolation behavior) of conductive filaments in a quasi-solid polymer electrode plotted as a function of volume fraction of conductive filaments (reduced graphene oxide sheets).

Fig. 6(a) la-tribute plot (gravimetric power density versus energy density) for Li-S cells containing S/CB composite particles as cathode active material and carbon nanofibers as conductive filaments. Three of the 4 data curves are for cells prepared according to embodiments of the invention, while the remaining one is a cell prepared by conventional electrode slurry coating (roll coating).

Fig. 6(B) cycling behavior of a conventional Li-S cell and a Li-S cell containing a quasi-solid polymer electrolyte and a quasi-solid polymer cathode.

Fig. 7(a) charting plots (gravimetric power density versus energy density) for Li-S cells containing graphene-supported S particles (S electrochemically deposited on the graphene surface) as the cathode active material and RGO as the conductive filament. Three of the 4 data curves are for cells prepared according to embodiments of the invention, while the remaining one is a cell prepared by conventional electrode paste coating (roll coating).

Fig. 7(B) cycling behavior of a conventional Li-S cell and a Li-S cell containing a quasi-solid polymer electrolyte and a quasi-solid polymer cathode.

Detailed Description

The present invention is directed to a lithium-sulfur or sodium-sulfur battery that exhibits an exceptionally high energy density that has never been achieved before. The battery may be a primary battery, but is preferably a secondary battery selected from a lithium ion-sulfur battery, a lithium metal-sulfur secondary battery (e.g., using lithium metal as an anode active material), a sodium ion-sulfur battery, or a sodium metal-sulfur battery (e.g., using sodium metal as an anode active material and carbon-supported sulfur as a cathode active material). The cell is based on a quasi-solid polymer electrolyte containing a polymer and lithium or sodium salt dissolved in water, an organic solvent, an ionic liquid, or a mixture of an organic liquid and an ionic liquid. Preferably, the electrolyte is a "quasi-solid polymer electrolyte" containing a high concentration of solute (lithium or sodium salt and polymer combination) in a solvent to the extent: it behaves like a solid but is deformable even when the desired amount of conductive filaments and active material are added to the electrolyte (hence the term "deformable quasi-solid polymer electrode"). The electrolyte is not a liquid electrolyte nor a solid electrolyte. The shape of the lithium battery may be cylindrical, square, button-like, etc. and may be a strange shape or an irregular shape. The present invention is not limited to any battery shape or configuration.

As shown in fig. 1(a), prior art lithium or sodium battery cells (including Li-S or room temperature Na-S cells) typically consist of an anode current collector (e.g., Cu foil), an anode electrode or anode active material layer (e.g., Li metal foil, sodium foil, or a pre-lithiated Si coating deposited on one or both sides of the Cu foil), a porous separator membrane and/or electrolyte component, a cathode electrode or cathode active material layer (or two cathode active material layers coated on both sides of the Al foil), and a cathode current collector (e.g., Al foil).

In a more common prior art cell construction (fig. 1(B)), the anode layer is composed of particles of anode active material (e.g., graphite, hard carbon, or Si), conductive additives (e.g., carbon black particles), and a resin binder (e.g., SBR or PVDF). The cathode layer is composed of cathode active material particles (e.g., LFP particles in Li-ion cells or lithium polysulfide/carbon composite particles in Li-S cells), conductive additives (e.g., carbon black particles), and a resin binder (e.g., PVDF). Both the anode and cathode layers are typically up to 100-200 μm thick to produce approximately sufficient current per unit electrode area. This range of thicknesses is considered an industry accepted constraint where battery designers typically work. This thickness constraint is due to several reasons: (a) existing battery electrode coating machines are not equipped to coat either too thin or too thick electrode layers; (b) thinner layers are preferred based on considerations of reduced lithium ion diffusion path length; but a layer that is too thin (e.g., <100 μm) does not contain a sufficient amount of active lithium storage material (and thus, the current output is insufficient); (c) thicker electrodes tend to delaminate or crack when dried or handled after roll coating; and (d) all inactive material layers (e.g., current collectors and separators) in the battery cell must be kept to a minimum in order to achieve minimum non-contributing weight and maximum lithium storage capacity, and thus maximum energy density (Wk/kg or Wh/L of the cell).

In a less common cell configuration, as shown in fig. 1(a), the anode active material (e.g., Si coating) or cathode active material is deposited in thin film form directly on a current collector such as a copper foil or Al foil. However, such thin film structures with extremely small thickness dimension (typically much less than 500nm, often necessarily thinner than 100nm) mean that only a small amount of active material can be incorporated into the electrode (given the same electrode or current collector surface area), providing low total lithium storage capacity and low lithium storage capacity per unit electrode surface area. Such films must have a thickness of less than 100nm to be more resistant to cycle-induced cracking (for the anode) or to facilitate full utilization of the cathode active material. This constraint further reduces the total lithium storage capacity and lithium storage capacity per unit electrode surface area. Such thin film batteries have a very limited range of applications.

On the anode side, Si layers thicker than 100nm have been found to exhibit poor resistance to cracking during the cell charge/discharge cycles. The fragmentation of the Si layer requires only a few cycles. On the cathode side, a sputtered layer of lithium metal oxide thicker than 100nm does not allow lithium ions to sufficiently penetrate and reach the entire cathode layer, resulting in poor utilization of the cathode active material. A desirable electrode thickness is at least 100 μm, with individual active material coatings or particles having a size desirably less than 100 nm. Therefore, these thin film electrodes deposited directly on the current collector (where the thickness is <100nm) are three (3) orders of magnitude lower than the desired thickness. As a further problem, all cathode active materials are not capable of conducting both electrons and lithium ions. A large layer thickness means an excessively high internal resistance and poor active material utilization. Sodium batteries have similar problems.

In other words, when dealing with the design and selection of cathode or anode active materials in terms of material type, size, electrode layer thickness, and active material mass loading, there are several conflicting factors that must be considered simultaneously. To date, any of the prior art teachings have not provided an effective solution to these often contradictory problems. We have solved these challenging problems that have plagued cell designers and electrochemists for more than 30 years by developing new methods of producing lithium or sodium cells as disclosed herein.

Prior art lithium battery cells are typically made by a process comprising the steps of: (a) the first step is to mix particles of the anode active material (e.g., Si nanoparticles or mesocarbon microbeads, MCMB), conductive fillers (e.g., graphite flakes), a resin binder (e.g., PVDF) in a solvent (e.g., NMP) to form an anode slurry. On a separate basis, cathode active material particles (e.g., LFP particles), a conductive filler (e.g., acetylene black), a resin binder (e.g., PVDF), and a solvent (e.g., NMP) are mixed and dispersed to form a cathode slurry. (b) The second step involves coating the anode slurry onto one or both major surfaces of an anode current collector (e.g., Cu foil), drying the coated layer by evaporating the solvent (e.g., NMP) to form a dried anode electrode coated on the Cu foil. Similarly, the cathode slurry was coated and dried to form a dried cathode electrode coated on Al foil. Slurry coating is usually carried out in a roll-to-roll manner in the actual manufacturing situation; (c) the third step involves laminating the anode/Cu foil, porous separator layer and cathode/Al foil together to form a 3-or 5-layer assembly, which is cut and slit to the desired size and stacked to form a rectangular structure (as an example of a shape) or wound into a cylindrical cell structure. (d) The rectangular or cylindrical laminate structure is then enclosed in an aluminum plastic laminate envelope or steel housing. (e) A liquid electrolyte is then injected into the laminate structure to produce a lithium battery cell.

There are several serious problems associated with this method and the resulting lithium battery cell:

1) it is very difficult to produce electrode layers (anode or cathode layers) thicker than 200 μm. There are several reasons for this to occur. Electrodes of 100-200 μm thickness typically require heating zones of 30-50 meters in length in a slurry coating facility, which is too time consuming, too energy consuming, and not cost effective. For some electrode active materials, such as metal oxide particles, it is not possible to produce electrodes of good structural integrity thicker than 100 μm on a continuous basis in a practical manufacturing environment. The resulting electrode is very fragile and brittle. Thicker electrodes have a high tendency to delaminate and crack.

2) With conventional approaches, as depicted in fig. 1(a), the actual mass loading of the electrode and the apparent density of the active material are too low to be achieved>A gravimetric energy density of 200 Wh/kg. In most cases, the anode active material mass loading (areal density) of the electrode is significantly below 25mg/cm ² And even for relatively large graphite particles, the apparent bulk or tap density of the active material is typically less than 1.2g/cm ³ . The cathode active material mass loading (areal density) of the electrode is significantly less than 45mg/cm for lithium metal oxide type inorganic materials ² And less than 15mg/cm for organic or polymeric materials ² . In addition, there are so many other inactive materials (e.g., conductive additives and resin binders) that the additional weight and volume of the electrode is increased without contributing to the cell capacity. These low areal and bulk densities result in relatively low gravimetric and bulk energy densities.

3) The conventional method requires that electrode active materials (an anode active material and a cathode active material) be dispersed in a liquid solvent (e.g., NMP) to manufacture a slurry, and when applied onto a current collector surface, the liquid solvent must be removed to dry the electrode layer. Once the anode and cathode layers are laminated together with the separator layer and encapsulated in a housing to produce a battery cell, a liquid electrolyte is then injected into the cell. In practice, the two electrodes are wetted, then the electrodes are dried and finally they are wetted again. This dry-wet-dry-wet method is not a good method at all.

4) Current lithium ion batteries still suffer from relatively low gravimetric energy density and relatively low volumetric energy density. Commercially available lithium ion batteries exhibit a gravimetric energy density of approximately 150-.

In the literature, energy density data reported based on active material weight or electrode weight alone cannot be directly translated into the energy density of an actual battery cell or device. The "non-contributing weight" or weight of other device components (adhesives, conductive additives, current collectors, separators, electrolytes, and encapsulants) must also be taken into account. Conventional production methods result in a weight proportion of anode active material (e.g. graphite or carbon) in the lithium ion battery typically from 12 to 17% and a weight proportion of cathode active material from 20 to 35% (for inorganic substances such as LiMn) ₂ O ₄ ) Or from 7% to 15% (for organic or polymeric cathode materials).

The present invention provides a lithium-sulfur battery or room temperature sodium-sulfur battery cell having high electrode thickness, high active material mass loading, low non-contributing weight and volume, high capacity, and high energy density. In certain embodiments, the present disclosure provides an alkali metal cell comprising: (a) a quasi-solid polymer cathode comprising from about 30% to about 95% by volume of a cathode active material (comprising a sulfur-containing cathode active material selected from the group consisting of sulfur, metal-sulfur compounds, sulfur-carbon composites, sulfur-graphene composites, sulfur-graphite composites, organosulfur compounds, sulfur-polymer composites, or combinations thereof), from about 5% to about 40% by volume of a first electrolyte comprising an alkali metal salt dissolved in a solvent and an ionically conductive polymer dissolved, dispersed, or impregnated by the solvent, and from about 0.01% to about 30% by volume of a conductive additive, wherein the conductive additive comprising conductive filaments forms a 3D network of electron conducting pathways, thereby providing the quasi-solid electrode with from about 10% to about 95% by volume of a cathode active material comprising a sulfur-containing cathode active material selected from the group consisting of sulfur, a metal-sulfur compound, a sulfur-carbon composite, a sulfur-graphene composite, a sulfur-graphite composite, an organosulfur compound, a sulfur-polymer composite, or combinations thereof, and from about 5% to about 40% by volume of a first electrolyte comprising an ionically conductive polymer dissolved in a solvent, wherein the conductive additive forms a 3D network of electron conducting pathways, thereby providing the quasi-solid electrode with a quasi-solid polymer cathode active material comprising a plurality of carbon-solid-carbon composite and a plurality of carbon-carbon composite ^-6 (iv) a conductivity of from S/cm to about 300S/cm (and possibly higher); (b) the anode (may be a conventional anode)Or quasi-solid polymer electrodes); and (c) an ion-conducting membrane or porous separator disposed between the anode and the quasi-solid cathode; wherein the quasi-solid cathode has a thickness of not less than 200 μm. The quasi-solid polymer cathode preferably contains not less than 10mg/cm ² Preferably not less than 15mg/cm ² Further preferably not less than 25mg/cm ² More preferably not less than 35mg/cm ² Still more preferably not less than 45mg/cm ² And most preferably greater than 65mg/cm ² Mass loading of cathode active material.

In the cell, the anode may also comprise a quasi-solid polymer anode comprising from about 30% to about 95% by volume of an anode active material, from about 5% to about 40% by volume of a second electrolyte comprising an alkali metal salt dissolved in a solvent and an ionically conductive polymer dissolved, dispersed, or impregnated with the solvent, and from about 0.01% to about 30% by volume of a conductive additive, wherein the conductive additive comprising electrically conductive filaments forms a 3D network of electron conduction pathways, such that the quasi-solid electrode has from about 10 ^-6 A conductivity of S/cm to about 300S/cm; wherein the quasi-solid anode has a thickness of not less than 200 μm. The quasi-solid anode preferably contains not less than 10mg/cm ² Preferably not less than 15mg/cm ² And further preferably not less than 25mg/cm ² More preferably not less than 35mg/cm ² Still more preferably not less than 45mg/cm ² And most preferably greater than 65mg/cm ² Mass loading of anode active material. The composition and structure of the first electrolyte may be the same as or different from the second electrolyte.

In some embodiments, the alkali metal battery contains a quasi-solid polymer anode, but contains a conventional cathode. Preferably, however, the cathode is a quasi-solid polymer electrode.

The invention also provides a method for producing the alkali metal battery. In certain embodiments, the method comprises:

(a) combining an amount of active material (anode active material or cathode active material), an amount of quasi-solid polymer electrolyte (containing a polymer and an alkali metal salt dissolved in a solvent), and a conductive additive to form a deformable and conductive electrode material, wherein the conductive additive containing conductive filaments forms a 3D network of electron conducting pathways; (these conductive filaments, such as carbon nanotubes and graphene sheets, are a large number of randomly aggregated filaments prior to mixing with the particles of active material and electrolyte

(b) Forming the electrode material as a quasi-solid electrode, wherein the forming step comprises deforming the electrode material into an electrode shape without interrupting the 3D network of electron conduction pathways, thereby causing the electrode to remain no less than 10 ^- ⁶ S/cm (preferably not less than 10) ^-5 S/cm, more preferably not less than 10 ^-4 S/cm, further preferably not less than 10 ^-3 S/cm, still more preferably and typically not less than 10 ^-2 S/cm, even more typically and preferably not less than 10 ^-1 An electrical conductivity of S/cm, and further more typically and preferably not less than 1S/cm; up to 300S/cm is observed);

(c) forming a second electrode (which may be a quasi-solid polymer electrode or a conventional electrode); and is

(d) Forming an alkali metal cell by combining the quasi-solid electrode and the second electrode, the alkali metal cell having an ion-conducting membrane disposed between the two electrodes.

As shown in fig. 1(C), one preferred embodiment of the invention is an alkali metal ion sulfur cell having a conductive quasi-solid polymer anode 236, a conductive quasi-solid polymer cathode 238 (containing a sulfur-containing cathode active material), and a porous separator 240 (or ion permeable membrane) that electronically separates the anode and cathode. These three components are typically enclosed in a protective housing (not shown) that typically has an anode tab (terminal) connected to the anode and a cathode tab (terminal) connected to the cathode. These tabs are used to connect to an external load (e.g., a battery-powered electronic device). In this particular embodiment, the quasi-solid polymer anode 236 contains an anode active material (e.g., particles of Li, Si, or hard carbon, not shown in fig. 1 (C)), an electrolyte phase (typically containing a lithium or sodium salt dissolved in a solvent and an ion conducting polymer dissolved in, dispersed in, or impregnated by the solvent); also not shown in fig. 1(C), and a conductive additive (containing conductive filaments) that forms the 3D network 244 of electron conducting pathways. Similarly, a quasi-solid polymer cathode contains a sulfur-containing cathode active material, an electrolyte, and a conductive additive (containing conductive filaments) that forms a 3D network 242 of electron conducting pathways.

Another preferred embodiment of the invention, as shown in fig. 1(D), is an alkali metal-sulfur cell with an anode comprised of a lithium or sodium metal coating/foil 282 deposited/attached to a current collector 280 (e.g., a Cu foil), a quasi-solid polymer cathode 284, and a separator or ion conducting membrane 282. The quasi-solid polymer cathode 284 contains a cathode active material 272 (e.g., porous carbon particles impregnated with S or lithium polysulfide, or composite particles containing S supported on graphene sheets), an electrolyte phase 274 (typically containing a lithium or sodium salt dissolved in a solvent and an ionically conductive polymer dissolved, dispersed, or impregnated with the solvent), and a conductive additive phase (containing conductive filaments) that forms a 3D network 270 of electron-conducting pathways.

The electrolyte is preferably a quasi-solid polymer electrolyte containing a lithium salt or sodium salt and a polymer dissolved in a solvent, the salt/polymer combination concentration being not less than 1.5M, preferably more than 2.5M, more preferably more than 3.5M, further preferably more than 5M, still more preferably more than 7M, and even more preferably more than 10M. In certain embodiments, the electrolyte is a quasi-solid polymer electrolyte containing a polymer and a lithium or sodium salt dissolved in a liquid solvent, with a combined salt/polymer concentration of from 3.0M to 14M. The selection of the lithium or sodium salt and the solvent is discussed further in the following section.

In some embodiments, the electrolyte contains a lithium ion conducting polymer or a sodium ion conducting polymer selected from the group consisting of: poly (ethylene oxide) (PEO, with less than 1x10 ⁶ Molecular weight of g/mol), polypropylene oxide (PPO), poly (propylene oxide)(acrylonitrile) (PAN), poly (methyl methacrylate) (PMMA), poly (vinylidene fluoride) (PVdF), poly (bis-methoxyethoxyethanol-phosphazene), polyvinyl chloride, polydimethylsiloxane, poly (vinylidene fluoride) -hexafluoropropylene (PVDF-HFP), sulfonated derivatives thereof, sulfonated polymers, or combinations thereof. It is found herein that sulfonation imparts improved lithium ion conductivity to the polymer. Higher than 1x10 ⁶ The molecular weight of PEO in g/mol typically makes PEO difficult to dissolve or disperse in a solvent.

Typically, the ion-conducting polymer does not form a matrix (continuous phase) in the electrode. Rather, the polymer is dissolved in the solvent as a solution phase or dispersed in the solvent matrix as a discrete phase. The resulting electrolyte is a quasi-solid polymer electrolyte; it is not a liquid electrolyte and not a solid electrolyte.

Both the quasi-solid anode and the quasi-solid cathode preferably have a thickness greater than 200 μm (preferably greater than 300 μm, more preferably greater than 400 μm, further preferably greater than 500 μm, still more preferably greater than 800 μm, further preferably greater than 1mm, and may be greater than 5mm, 1cm, or more ² (more typically and preferably not less than 20 mg/cm) ² And more preferably not less than 30mg/cm ² ) Electrode active material loading. For inorganic materials as the cathode active material, the cathode active material composition is not less than 45mg/cm ² (typically and preferably greater than 50 mg/cm) ² And more preferably greater than 60mg/cm ² ) Electrode active material mass loading (not less than 25mg/cm for organic or polymeric cathode active materials) ² )。

In such configurations (fig. 1(C) and 1(D)), the electrons need only travel a short distance (e.g., a few microns or less) before they are collected by the conductive filaments that make up the 3D network of electron conducting pathways and are present everywhere in the overall quasi-solid polymer electrode (anode or cathode). In addition, all electrode active material particles are pre-dispersed in electrolyte solvent (no wettability issues), eliminating the presence of dry pockets typically found in electrodes prepared by conventional methods of wet coating, drying, packaging and electrolyte injection. Thus, the process of the present invention has a completely unexpected advantage over conventional battery cell production processes.

These conductive filaments (e.g., carbon nanotubes and graphene sheets) as supplied are initially a large number of randomly aggregated filaments before being mixed with the particles of active material and electrolyte. The mixing procedure may involve dispersing these conductive filaments in a highly viscous solid-like electrolyte containing particles of the active material. This is not a trivial task as one might think. It has been known that the dispersion of nanomaterials (particularly nanofilament materials such as carbon nanotubes, carbon nanofibers, and graphene sheets) in highly flowable (non-viscous) liquids is difficult, not to mention in highly viscous quasi-solids, such as electrolytes containing high loadings of active materials (e.g., solid particles such as Si nanoparticles for anodes and lithium cobalt oxide for cathodes). In some preferred embodiments, this problem is further exacerbated by the following viewpoints: the electrolyte itself is a quasi-solid polymer electrolyte containing a high concentration of lithium or sodium salt and a polymer in a solvent.

In some embodiments of the present invention, the formation of the electrode layer may be accomplished by using the following sequence of steps:

sequence 1 (S1): the lithium or sodium salt (e.g., LiBF) may be first reacted ₄ ) And an ion conducting polymer (e.g., PEO) is dissolved in the mixture of PC and DOL to form an electrolyte with a desired salt/polymer combination concentration. Then, conductive filaments (e.g., carbon nanofibers, reduced graphene oxide sheets, or CNTs) are dispersed in an electrolyte to form a filament-electrolyte suspension. Mechanical shear may be used to help form a uniform dispersion. (the filament-electrolyte suspension is quite viscous even at low salt concentrations of 1.0M). Particles of cathode active material (e.g., S/carbon composite particles) are then dispersed in the filament-electrolyte suspension to form a quasi-solid polymer electrode material.

Sequence 2 (S2): the lithium or sodium salt and the ion conducting polymer are first dissolved in a mixture of PC and DOL to form an electrolyte having the desired salt/polymer combination concentration. Then, the cathode active material particles are dispersed in the electrolyte to form an active particle-electrolyte suspension. Mechanical shear may be used to help form a uniform dispersion. The conductive filaments are then dispersed in an active particle-electrolyte suspension to form a quasi-solid polymer electrode material.

Sequence 3 (S3): this is the preferred order. First, a desired amount of conductive filaments are dispersed in a liquid solvent mixture (e.g., PC + DOL) that does not contain a dissolved lithium salt or polymer therein. Mechanical shearing may be used to help form a uniform suspension of the conductive filaments in the solvent. A lithium or sodium salt and an ion conducting polymer are then added to the suspension, thereby dissolving the salt and the polymer in the solvent mixture of the suspension to form an electrolyte having the desired salt/polymer combination concentration. Simultaneously or subsequently, active material particles are dispersed in an electrolyte to form a deformable quasi-solid electrode material composed of active material particles and conductive filaments dispersed in a quasi-solid polymer electrolyte (not a liquid electrolyte and not a solid electrolyte). In the quasi-solid electrode material, the conductive filaments are percolated to form a 3D network of electron conducting pathways. The 3D conductive network is maintained when the electrode material is formed into an electrode of a battery.

In some preferred embodiments, the electrolyte contains a polymer and an alkali metal salt (lithium salt and/or sodium salt) dissolved in an organic or ionic liquid solvent, where the alkali metal salt/polymer combination concentration is sufficiently high such that the electrolyte exhibits a vapor pressure (when measured at 20 ℃) that is less than 0.01kPa or less than 0.6 (60%) of the vapor pressure of the solvent alone, a flash point that is at least 20 degrees celsius higher than the flash point of the first organic liquid solvent alone (when no lithium salt is present), a flash point that is higher than 150 ℃, or no detectable flash point at all.

Of most surprising and great scientific and technical importance is our finding that: the flammability of any volatile organic solvent can be effectively suppressed provided that sufficiently high amounts of alkali metal salt and polymer are added to and dissolved in the organic solvent to form a solid-like or quasi-solid polymer electrolyte. Generally, such quasi-solid polymer electrolytes exhibit a vapor pressure of less than 0.01kPa and often less than 0.001kPa (when measured at 20 ℃) and often less than 0.1kPa and often less than 0.01kPa (when measured at 100 ℃). (the vapor pressure of the corresponding pure solvent in which none of the alkali metal salt and/or polymer is dissolved is typically significantly higher.) in many cases characterized by quasi-solid polymer electrolytes, the vapor molecules are actually too few to be detected.

Very important observations are: the high solubility (macromolecular ratio or mole fraction of alkali metal salt/polymer segment, typically >0.2, more typically >0.3, and often >0.4 or even >0.5) of the combined alkali metal salt and polymer in an otherwise highly volatile solvent can significantly reduce the amount of volatile solvent molecules that can escape into the vapor phase under thermodynamic equilibrium conditions. In many cases, this effectively prevents flammable solvent gas molecules from initiating the flame, even at extremely high temperatures (e.g., using a torch). The flash point of quasi-solid polymer electrolytes is typically at least 20 degrees (often >50 or >100 degrees) higher than the flash point of the pure organic solvent alone. In most cases, the flash point is above 150 ℃ or no flash point can be detected. The electrolyte will not ignite. Furthermore, any accidental fire does not last longer than a few seconds. This is a very important finding in view of the fire and explosion concerns that have been a major obstacle to the widespread acceptance of battery powered electric vehicles. This new technology can significantly help accelerate the rise of the live EV industry.

For safety reasons, no studies have been previously reported on the vapor pressure of ultra-high concentration battery electrolytes (alkali metal salt/polymer segments or combined concentrations of approximately >2.5M or 3.5M with high molecular fractions, e.g., >0.2 or > 0.3). This is indeed unexpected and of great technical and scientific significance.

We have further unexpectedly found that: the presence of a 3D network of electron conducting pathways composed of conductive filaments serves to further reduce the threshold concentration of alkali metal salt required to achieve critical vapor pressure suppression.

Another surprising element of the present invention is the following point: we are able to dissolve high concentrations of alkali metal salts and selected ion conducting polymers in almost every type of commonly used battery grade organic solvent to form quasi-solid polymer electrolytes suitable for rechargeable alkali metal batteries. Expressed in more readily recognized terms, the concentration is typically greater than 2.5M (moles/liter), more typically and preferably greater than 3.5M, still more typically and preferably greater than 5M, still more preferably greater than 7M, and most preferably greater than 10M. In the case of a salt/polymer concentration of not less than 2.5M, the electrolyte is no longer a liquid electrolyte; rather, it is a quasi-solid electrolyte. Such high concentrations of alkali metal salts in solvents are generally considered impossible, nor desirable, in the field of lithium or sodium batteries. However, we have found that these quasi-solid polymer electrolytes are surprisingly good electrolytes for both lithium and sodium batteries in terms of significantly improved safety (non-flammability), improved energy density and improved power density.

In addition to the non-flammability and high alkali metal ion transfer number as discussed above, there are several other benefits to using the quasi-solid polymer electrolytes of the present invention. For example, quasi-solid polymer electrolytes, when implemented at least in anodes, can significantly enhance re-producible electrodes by effectively inhibiting dendritic growthCycling and safety performance of rechargeable alkali-sulfur batteries. It is generally believed that dendrites begin to grow in the non-aqueous liquid electrolyte when anions are depleted near the electrode where plating occurs. In ultra-high concentration electrolytes, there are a large number of anions to retain cations (Li) near the metallic lithium or sodium anode ⁺ Or Na ⁺ ) And anions. In addition, the space charge generated by anion depletion is extremely small, which is detrimental to dendrite growth. In addition, due to the ultra-high Li or Na salt concentration and the high Li ion or Na ion transfer number, the quasi-solid polymer electrolyte provides a large amount of available lithium ion or sodium ion flux and increases the lithium or sodium ion mass transfer rate between the electrolyte and the lithium or sodium electrode, thereby enhancing the deposition uniformity and dissolution of lithium or sodium during charge/discharge. In addition, the locally high viscosity caused by the high concentration will increase the pressure from the electrolyte to inhibit dendrite growth, potentially resulting in a more uniform deposition on the anode surface. The high viscosity may also limit anion convection near the deposition area, thereby promoting more uniform deposition of sodium ions. The same reasoning applies to lithium metal batteries. These reasons are believed to be (individually or in combination) the reasons for the following: to date, no dendrite-like features have been observed for any of the large number of rechargeable alkali metal-sulfur cells we studied.

Furthermore, one skilled in the art of chemical or material science would expect that such high salt/polymer concentrations should cause the electrolyte to behave like a solid with very high viscosity, and therefore, the electrolyte should not be suitable for rapid diffusion of alkali metal ions therein. Thus, one skilled in the art would expect that an alkali metal battery containing such a solid-like polymer electrolyte would not and cannot exhibit high capacity (i.e., the battery should have poor rate performance) at high charge-discharge rates or under high current density conditions. Contrary to these expectations of the skilled person or even an outstanding skilled person, all alkali metal-sulphur cells containing such quasi-solid polymer electrolytes impart a high energy density and a high power density, thereby achieving a long cycle life. It appears that quasi-solid polymer electrolytes as invented and disclosed herein are advantageousEasy alkali metal ion transport. This unexpected finding may be due to two main factors: one associated with the internal structure of the electrolyte and the other with high Na ⁺ Or Li ⁺ Ion Transfer Number (TN) is relevant.

Without wishing to be bound by theory, the internal structure of three fundamentally different types of electrolytes can be visualized by reference to fig. 2(a) to 2 (C). Fig. 2(a) schematically shows a close-packed highly ordered structure of a typical solid electrolyte, in which there is little free volume for diffusion of alkali metal ions. Any migration of ions in such a crystal structure is very difficult, resulting in a very low diffusion coefficient (10) ^-16 To 10 ^-12 cm ² S) and extremely low ionic conductivity (typically from 10) ^-7 S/cm to 10 ^-4 S/cm). In contrast, as schematically shown in fig. 2(B), the internal structure of the liquid electrolyte is completely amorphous, having cations (e.g., or Li) ⁺ Or Na ⁺ ) Large free volume fraction that can easily migrate through, resulting in a high diffusion coefficient (10) ^-8 To 10 ^-6 cm ² S) and high ionic conductivity (typically from 10) ^-3 S/cm to 10 ^-2 S/cm). However, liquid electrolytes containing low concentrations of alkali metal salts are flammable and prone to dendrite formation, creating a fire and explosion hazard. Schematically illustrated in fig. 2(C) is the random or amorphous structure of a quasi-solid polymer electrolyte with solvent molecules separating the salt species and polymer segments to create amorphous regions that facilitate migration of free (unclustered) cations. Such a structure is suitable for achieving high ionic conductivity values (typically 10) ^-4 S/cm to 8x 10 ^-3 S/cm) but remain nonflammable. Relatively few solvent molecules are present and these molecules are retained (against evaporation) by overwhelmingly large amounts of salt species, polymer segments and networks of conductive filaments.

In the Li-S or Na-S cells of the invention, the anode typically contains Li or Na metal in the form of a metal foil, thin film, or thin coating (thickness <50 μm) deposited on a current collector (e.g., Cu foil or 3D graphene nanostructures).

In some embodiments, the anode active material is a pre-lithiated or pre-sodiated version of graphene sheets selected from pristine graphene, graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, chemically functionalized graphene, or a combination thereof. The starting graphite material used to produce any of the above graphene materials may be selected from natural graphite, artificial graphite, mesophase carbon, mesophase pitch, mesophase carbon microbeads, soft carbon, hard carbon, coke, carbon fibers, carbon nanofibers, carbon nanotubes, or combinations thereof. Graphene materials are also good conductive additives for anode and cathode active materials of lithium batteries.

The constituent graphene planes of graphite crystallites in natural or artificial graphite particles can be expanded and extracted or isolated to obtain single graphene sheets of hexagonal carbon atoms that are monoatomic in thickness, provided that the interplanar van der waals forces can be overcome. One method of production is shown in figure 4. An isolated single graphene plane of carbon atoms is commonly referred to as single layer graphene. A stack of a plurality of graphene planes bonded by van der waals force in the thickness direction with a spacing between the graphene planes of about 0.3354nm is generally referred to as multi-layered graphene. The multi-layered graphene platelets have up to 300 graphene planes (< 100nm in thickness), but more typically up to 30 graphene planes (< 10nm in thickness), even more typically up to 20 graphene planes (< 7nm in thickness), and most typically up to 10 graphene planes (commonly referred to as few-layer graphene in the scientific community). Single-layer graphene sheets and multi-layer graphene sheets are collectively referred to as "nano-graphene platelets" (NGPs). Graphene sheets/platelets (collectively referred to as NGP) are a new class of carbon nanomaterials (2-D nanocarbons) that differ from 0-D fullerenes, 1-D CNTs, or CNFs and 3-D graphites. For the purposes of defining the claims and as generally understood in the art, the graphene material (isolated graphene sheets) is not (and does not include) Carbon Nanotubes (CNTs) or Carbon Nanofibers (CNFs).

In one method, the graphite intercalation compound is obtained by intercalating natural graphite particles with a strong acid and/or an oxidizing agent(s) ((II))GIC) or Graphite Oxide (GO) to obtain graphene materials, as shown in fig. 5. The presence of chemical species or functional groups in the interstitial spaces between graphene planes in a GIC or GO serves to increase the inter-graphene spacing (d) ₀₀₂ As determined by X-ray diffraction) to thereby significantly reduce van der waals forces that would otherwise hold graphene planes together along the c-axis direction. GIC or GO is most often produced by immersing natural graphite powder in a mixture of sulfuric acid, nitric acid (the oxidant) and another oxidant, such as potassium permanganate or sodium perchlorate. If an oxidizing agent is present during the intercalation procedure, the resulting GIC is actually some type of Graphite Oxide (GO) particles. The GIC or GO is then repeatedly washed and rinsed in water to remove excess acid, producing a graphite oxide suspension or dispersion containing discrete and visually identifiable graphite oxide particles dispersed in water. To produce graphene materials, one of two processing routes may be followed after this washing step, briefly described below:

route 1 involves the removal of water from the suspension to obtain "expandable graphite", which is essentially a mass of dry GIC or dry graphite oxide particles. Upon exposure of the expandable graphite to temperatures in the range of from typically 800 c to 1,050 c for about 30 seconds to 2 minutes, the GIC undergoes 30-300 times rapid volume expansion to form "graphite worms," each of which is an assemblage of expanded, yet interconnected, largely unseparated graphite flakes.

In route 1A, these graphite worms (expanded graphite or "network of interconnected/unseparated graphite flakes") can be recompressed to obtain flexible graphite sheets or foils, typically having a thickness in the range from 0.1mm (100 μm) to 0.5mm (500 μm). Alternatively, the use of low intensity air mills or shears may be chosen to simply disintegrate the graphite worms for the purpose of producing so-called "expanded graphite flakes" which contain predominantly graphite flakes or platelets (and are therefore not nanomaterials by definition) that are thicker than 100 nm.

In route 1B, expanded graphite is subjected to high intensity mechanical shearing (e.g., using an ultrasonic generator, a high shear mixer, a high intensity air jet mill, or a high energy ball mill) to form separate single and multi-layer graphene sheets (collectively referred to as NGPs), as disclosed in our application US20050271574 (12/8/2005). Single-layer graphene can be as thin as 0.34nm, while multi-layer graphene can have a thickness of up to 100nm, but more typically less than 10nm (commonly referred to as few-layer graphene). A plurality of graphene sheets or platelets may be made into a sheet of NGP paper using a papermaking process. The NGP paper sheet is an example of a porous graphene structure layer used in the method of the present invention.

Route 2 entails subjecting a graphite oxide suspension (e.g., graphite oxide particles dispersed in water) to ultrasonic treatment for the purpose of separating/isolating individual graphene oxide sheets from the graphite oxide particles. This is based on the following point: the spacing between graphene planes has increased from 0.3354nm in natural graphite to 0.6-1.1nm in highly oxidized graphite oxide, significantly reducing van der waals forces holding adjacent planes together. The ultrasonic power may be sufficient to further separate the graphene planar sheets to form fully separated, isolated or discrete Graphene Oxide (GO) sheets. These graphene oxide sheets may then be chemically or thermally reduced to obtain "reduced graphene oxide" (RGO), typically having an oxygen content of 0.001-10% by weight, more typically 0.01-5% by weight, most typically and preferably less than 2% by weight oxygen.

For the purposes of defining the claims of the present application, NGP or graphene materials include single and multiple layers (typically less than 10 layers) of discrete sheets/platelets of pristine graphene, graphene oxide, Reduced Graphene Oxide (RGO), graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, chemically functionalized graphene, doped graphene (e.g. doped with B or N). Pristine graphene has substantially 0% oxygen. RGO typically has an oxygen content of 0.001% -5% by weight. Graphene oxide (including RGO) may have 0.001% -50% oxygen by weight. All graphene materials, except pristine graphene, have 0.001% -50% by weight of non-carbon elements (e.g., O, H, N, B, F, Cl, Br, I, etc.). These materials are referred to herein as non-native graphene materials.

Pristine graphene, in the form of smaller discrete graphene sheets (typically 0.3 to 10 μm), can be produced by direct sonication (also known as liquid phase expansion or production) or supercritical fluid expansion of graphite particles. These methods are well known in the art.

Graphene Oxide (GO) may be obtained by immersing a powder or filament of a starting graphite material (e.g. natural graphite powder) in an oxidizing liquid medium (e.g. a mixture of sulfuric acid, nitric acid and potassium permanganate) in a reaction vessel at a desired temperature for a period of time (typically from 0.5 to 96 hours, depending on the nature of the starting material and the type of oxidant used). As previously described above, the resulting graphite oxide particles may then be subjected to thermal or ultrasound induced expansion to produce isolated GO sheets. And then by using other chemical groups (e.g. -Br, NH) ₂ Etc.) substitution of-OH groups converts these GO sheets into various graphene materials.

Fluorinated graphene or graphene fluoride are used herein as examples of halogenated graphene material groups. There are two different approaches that have been followed to produce fluorinated graphene: (1) fluorination of pre-synthesized graphene: the process requires the use of a fluorinating agent such as XeF ₂ Or F-based plasma treatment of graphene prepared by mechanical expansion or by CVD growth; (2) puffing the multilayer graphite fluoride: both mechanical and liquid phase expansion of graphite fluoride can be readily achieved.

F ₂ Interaction with graphite at high temperatures results in covalent graphite fluoride (CF) _n Or (C) ₂ F) _n While forming Graphite Intercalation Compound (GIC) C at low temperature _x F (x is more than or equal to 2 and less than or equal to 24). In (CF) _n The carbon atoms are sp3 hybridized and thus the fluorocarbon layer is corrugated, consisting of trans-linked cyclohexane chairs. In (C) ₂ F) _n Only half of the C atoms are fluorinated and each pair of adjacent carbon sheets are linked together by a covalent C — C bond. Systematic studies of the fluorination reactions showed that the F/C ratios obtained were very highDepending in large part on the fluorination temperature, the partial pressure of fluorine in the fluorination gas, and the physical characteristics of the graphite precursor, including the degree of graphitization, particle size, and specific surface area. In addition to fluorine (F) ₂ ) In addition, other fluorinating agents may be used, although most of the prior art references refer to the use of F ₂ The gas is fluorinated (sometimes in the presence of fluoride).

In order to expand the layered precursor material into the state of a single layer or several layers, the attractive forces between adjacent layers must be overcome and the layers further stabilized. This can be achieved by covalent modification of the graphene surface with functional groups or by non-covalent modification using specific solvents, surfactants, polymers, or donor-acceptor aromatic molecules. The liquid phase expansion process involves ultrasonication of graphite fluoride in a liquid medium.

Nitridation of graphene can be performed by exposing the graphene material (e.g., graphene oxide) to ammonia at high temperatures (200-400 ℃). The graphene nitride can be formed at a lower temperature by a hydrothermal method; for example by sealing GO and ammonia in an autoclave and then warming to 150-250 ℃. Other methods of synthesizing nitrogen-doped graphene include nitrogen plasma treatment on graphene, arc discharge between graphite electrodes in the presence of ammonia, ammonolysis of graphene oxide under CVD conditions, and hydrothermal treatment of graphene oxide and urea at different temperatures.

There is no limitation on the type of anode active material that can be used in the practice of the present invention. Preferably, in the lithium-sulfur cell of the present invention, the anode active material exceeds Li/Li when the battery is charged ⁺ (i.e. with respect to Li → Li as the standard potential) ⁺ +e ^- ) The lithium ions are absorbed at an electrochemical potential of less than 1.0 volt, preferably less than 0.7 volt. In a preferred embodiment, the anode active material of the lithium battery is selected from the group consisting of: (a) particles of lithium metal or lithium metal alloy; (b) natural graphite particles, artificial graphite particles, mesocarbon microbeads (MCMB), carbon particles (including soft and hard carbon), needle coke, carbon nanotubes, carbon nanofibers, carbon fibers, and graphite fibers; (c) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Z)n), aluminum (Al), nickel (Ni), cobalt (Co), manganese (Mn), titanium (Ti), iron (Fe), and cadmium (Cd); (d) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al or Cd with other elements, wherein the alloys or compounds are stoichiometric or non-stoichiometric; (e) oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ni, Co, Ti, Mn, or Cd, and mixtures or composites thereof; (f) a prelithiated version thereof; (g) pre-lithiated graphene sheets; and combinations thereof.

In certain embodiments, the alkali metal-sulfur cell is a sodium ion-sulfur cell and the active material is an anode active material comprising a sodium intercalation compound selected from: petroleum coke, carbon black, amorphous carbon, activated carbon, hard carbon (hard graphitizable carbon), soft carbon (graphitizable carbon), template carbon, hollow carbon nanowire, hollow carbon sphere, titanate, NaTi ₂ (PO ₄ ) ₃ 、Na ₂ Ti ₃ O ₇ 、Na ₂ C ₈ H ₄ O ₄ 、Na ₂ TP、Na _x TiO ₂ (x-0.2 to 1.0), Na ₂ C ₈ H ₄ O ₄ Materials based on carboxylic acid salts, C ₈ H ₄ Na ₂ O ₄ 、C ₈ H ₆ O ₄ 、C ₈ H ₅ NaO ₄ 、C ₈ Na ₂ F ₄ O ₄ 、C ₁₀ H ₂ Na ₄ O ₈ 、C ₁₄ H ₄ O ₆ 、C ₁₄ H ₄ Na ₄ O ₈ Or a combination thereof.

In certain embodiments, the alkali metal-sulfur cell is a sodium metal-sulfur cell or a sodium ion-sulfur cell and the active material is an anode active material selected from the group consisting of: (a) particles of sodium metal or sodium metal alloy; (b) natural graphite particles, artificial graphite particles, mesocarbon microbeads (MCMB), carbon particles, needle coke, carbon nanotubes, carbon nanofibers, carbon fibers, and graphite fibers; (c) sodium-doped silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), cobalt (Co), nickel (Ni), manganese (Mn), cadmium (Cd), and mixtures thereof; (d) sodium-containing alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Co, Ni, Mn, Cd, and mixtures thereof; (e) sodium-containing oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides, or antimonides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ti, Co, Ni, Mn, Cd, and mixtures or composites thereof; (f) a sodium salt; and (g) graphene sheets pre-loaded with sodium ions; and combinations thereof.

The lithium-sulfur or sodium-sulfur cells of the invention can be practiced using a wide variety of sulfur-based cathode active materials. Such sulfur-containing cathode active materials may be selected from sulfur, metal-sulfur compounds (e.g., lithium polysulfides), sulfur-carbon composites (e.g., carbon black-S composites prepared by ball milling, or porous carbon particles impregnated with S), sulfur-graphene composites, sulfur-graphite composites, organosulfur compounds, sulfur-polymer composites, or combinations thereof.

In some embodiments, the cathode active material may be selected from sulfur or sulfur compounds supported by or associated with the functional or nanostructured material. The functional or nanostructured material may be selected from the group consisting of: (a) nanostructured or porous disordered carbon materials selected from soft carbon, hard carbon, polymeric or carbonized resins, mesophase carbon, coke, carbonized pitch, carbon black, activated carbon, nano-cellular carbon foam, or partially graphitized carbon; (b) nano-graphene platelets selected from single-layer graphene sheets or multi-layer graphene platelets; (c) carbon nanotubes selected from single-walled carbon nanotubes or multi-walled carbon nanotubes; (d) carbon nanofibers, nanowires, metal oxide nanowires or fibers, conductive polymer nanofibers, or a combination thereof; (e) carbonyl-containing organic or polymeric molecules; (f) functional materials containing carbonyl, carboxyl or amino groups; and combinations thereof.

The functional or nanostructured material may be selected from the group consisting of: poly (2, 5-dihydroxy-1, 4-benzoquinone-3, 6-methylene) and Na _x C ₆ O ₆ (x＝1-3)、Na ₂ (C ₆ H ₂ O ₄ )、Na ₂ C ₈ H ₄ O ₄ (sodium terephthalate), Na ₂ C ₆ H ₄ O ₄ (sodium trans-muconate), 3,4,9, 10-perylenetetracarboxylic-dianhydride (PTCDA) sulfide polymer, PTCDA, 1,4,5, 8-naphthalenetetracarboxylic-dianhydride (NTCDA), benzene-1, 2,4, 5-tetracarboxylic-dianhydride, 1,4,5, 8-tetrahydroxyanthraquinone, tetrahydroxy-p-benzoquinone, and combinations thereof. Desirably, the functional or nanostructured material has a structure selected from-COOH, ═ O, -NH ₂ -OR OR-COOR, wherein R is a hydrocarbyl group.

Non-graphene 2D nanomaterials (single or few layers (up to 20 layers)) can be produced by several methods: mechanical cleaving, laser ablation (e.g., ablation of TMD into a single layer using laser pulses), liquid phase expansion, and synthesis by thin film techniques such as PVD (e.g., sputtering), evaporation, vapor phase epitaxy, liquid phase epitaxy, chemical vapor phase epitaxy, Molecular Beam Epitaxy (MBE), Atomic Layer Epitaxy (ALE), and plasma assisted versions thereof.

A wide range of electrolytes can be used in the practice of the present invention. Most preferred are non-aqueous organic and/or ionic liquid electrolytes. The nonaqueous electrolyte to be used herein may be produced by dissolving an electrolyte salt in a nonaqueous solvent. Any known non-aqueous solvent that has been used as a solvent for a lithium secondary battery may be used. It may be preferable to use a nonaqueous solvent mainly composed of a mixed solvent containing Ethylene Carbonate (EC) and at least one kind of a nonaqueous solvent (hereinafter referred to as a second solvent) having a melting point lower than the above-mentioned ethylene carbonate and having a donor number of 18 or less. This non-aqueous solvent is advantageous because it: (a) is stable to negative electrodes containing carbonaceous materials that develop well in graphite structures; (b) effectively inhibit the reduction or oxidation decomposition of the electrolyte; and (c) high conductivity. A non-aqueous electrolyte consisting of Ethylene Carbonate (EC) alone is advantageous because it is relatively stable to decomposition by reduction of the graphitized carbonaceous material. However, the melting point of EC is relatively high, 39 ℃ to 40 ℃, and its viscosity is relatively high, so that its electrical conductivity is low, thus making EC alone unsuitable for use as a secondary battery electrolyte operating at room temperature or lower. The second solvent to be used with the EC in the mixture functions to lower the viscosity of the solvent mixture than the viscosity of the EC alone, thereby promoting the ionic conductivity of the mixed solvent. Further, when the second solvent having the donor number of 18 or less (the donor number of ethylene carbonate is 16.4) is used, the above-described ethylene carbonate can be easily and selectively solvated with lithium ions, so that the reduction reaction of the second solvent with the carbon-containing material which is supposed to well progress in graphitization is suppressed. Further, when the donor number of the second solvent is controlled to not more than 18, the oxidative decomposition potential of the lithium electrode can be easily increased to 4V or more, so that a high-voltage lithium secondary battery can be manufactured.

Preferred second solvents are dimethyl carbonate (DMC), ethyl methyl carbonate (MEC), diethyl carbonate (DEC), ethyl propionate, methyl propionate, Propylene Carbonate (PC), gamma-butyrolactone (gamma-BL), Acetonitrile (AN), Ethyl Acetate (EA), Propyl Formate (PF), Methyl Formate (MF), toluene, xylene and Methyl Acetate (MA). These second solvents may be used alone or in combination of two or more. More desirably, the second solvent should be selected from those having a donor number of 16.5 or less. The viscosity of the second solvent should preferably be 28cps or less at 25 ℃.

The mixing ratio of the above ethylene carbonate in the mixed solvent should preferably be 10% to 80% by volume. If the mixing ratio of ethylene carbonate falls outside this range, the conductivity of the solvent may decrease or the solvent tends to decompose more easily, thereby deteriorating the charge/discharge efficiency. More preferably, the mixing ratio of ethylene carbonate is 20% to 75% by volume. When the mixing ratio of ethylene carbonate in the nonaqueous solvent is increased to 20% by volume or more, the solvating effect of ethylene carbonate on lithium ions is promoted and the solvolysis suppressing effect thereof can be improved.

Examples of preferred mixed solvents are those comprising EC and MEC; comprises EC, PC and MEC; comprises EC, MEC and DEC; comprises EC, MEC and DMC; and compositions comprising EC, MEC, PC and DEC; wherein the volume ratio of the MEC is controlled to be in the range of from 30% to 80%. By selecting a volume of MEC in the range of from 30% to 80%, more preferably 40% to 70%Ratio, the conductivity of the solvent can be improved. For the purpose of suppressing the decomposition reaction of the solvent, an electrolyte having carbon dioxide dissolved therein may be used, thereby effectively improving both the capacity and the cycle life of the battery. The electrolyte salt to be incorporated into the non-aqueous electrolyte may be selected from lithium salts such as lithium perchlorate (LiClO) ₄ ) Lithium hexafluorophosphate (LiPF) ₆ ) Lithium fluoroborate (LiBF) ₄ ) Lithium hexafluoroarsenate (LiAsF) ₆ ) Lithium trifluoromethanesulfonate (LiCF) ₃ SO ₃ ) And lithium bistrifluoromethylsulfonyl imide [ LiN (CF) ₃ SO ₂ ) ₂ ]. Wherein, LiPF ₆ 、LiBF ₄ And LiN (CF) ₃ SO ₂ ) ₂ Is preferred. The content of the above electrolyte salt in the non-aqueous solvent is preferably 0.5 to 2.0 mol/l.

For sodium cells, the electrolyte (including the nonflammable quasi-solid electrolyte) may contain a sodium salt preferably selected from: sodium perchlorate (NaClO) ₄ ) Sodium hexafluorophosphate (NaPF) ₆ ) Sodium fluoroborate (NaBF) ₄ ) Sodium hexafluoroarsenate, sodium trifluoro-methanesulfonate (NaCF) ₃ SO ₃ ) Bis-trifluoromethylsulfonyl imide sodium salt (NaN (CF) ₃ SO ₂ ) ₂ ) An ionic liquid salt, or a combination thereof.

Ionic liquids are composed of ions only. Ionic liquids are low melting point salts that are molten or liquid when above a desired temperature. For example, a salt is considered an ionic liquid if it has a melting point below 100 ℃. If the melting temperature is equal to or lower than room temperature (25 ℃), the salt is referred to as a Room Temperature Ionic Liquid (RTIL). Due to the combination of large cations and charge delocalized anions, IL salts are characterized by weak interactions. This results in a low tendency to crystallize due to flexibility (anions) and asymmetry (cations).

Typical and well-known ionic liquids are formed by the combination of a 1-ethyl-3-methylimidazolium (EMI) cation and an N, N-bis (trifluoromethane) sulfonamide (TFSI) anion. This combination results in a fluid having an ionic conductivity comparable to many organic electrolyte solutions and a low decomposition tendency and low vapor pressure of up to about 300-400 ℃. This means an electrolyte that is generally low in volatility and non-flammability, and is therefore much safer for batteries.

Ionic liquids are essentially composed of organic ions and, due to the ease of preparation of their various components, have an essentially unlimited number of structural changes. Thus, various salts can be used to design an ionic liquid having desired characteristics for a given application. These include inter alia imidazolium, pyrrolidinium and quaternary ammonium salts as cations and bis (trifluoromethanesulfonyl) imide, bis (fluorosulfonyl) imide and hexafluorophosphate as anions. Based on their composition, ionic liquids come in different classes, which basically include aprotic, protic and zwitterionic types, each suitable for a particular application.

Common cations for Room Temperature Ionic Liquids (RTILs) include, but are not limited to, tetraalkylammonium, di-, tri-, and tetra-alkylimidazolium, alkylpyridinium, dialkyl-pyrrolidinium, dialkyl piperidinium, tetraalkylphosphonium, and trialkyl sulfonium. Common anions for RTILs include, but are not limited to, BF ₄ ^- 、B(CN) ₄ ^- 、CH ₃ BF ₃ ^- 、CH2CHBF ₃ ^- 、CF ₃ BF ₃ ^- 、C ₂ F ₅ BF ₃ ^- 、n-C ₃ F ₇ BF ₃ ^- 、n-C ₄ F ₉ BF ₃ ^- 、PF ₆ ^- 、CF ₃ CO ₂ ^- 、CF ₃ SO ₃ ^- 、N(SO ₂ CF ₃ ) ₂ ^- 、N(COCF ₃ )(SO ₂ CF ₃ ) ^- 、N(SO ₂ F) ₂ ^- 、N(CN) ₂ ^- 、C(CN) ₃ ^- 、SCN ^- 、SeCN ^- 、CuCl ₂ ^- 、AlCl ₄ ^- 、F(HF) _2.3 ^- And the like. In contrast, imidazolium-or sulfonium-based cations with, for example, AlCl ₄ ^- 、BF ₄ ^- 、CF ₃ CO ₂ ^- 、CF ₃ SO ₃ ^- 、NTf ₂ ^- 、N(SO ₂ F) ₂ ^- Or F (HF) _2.3 ^- The combination of isocomplex halide anions results in an RTIL with good working conductivity.

RTILs can have typical characteristics such as high intrinsic ionic conductivity, high thermal stability, low volatility, low (almost zero) vapor pressure, non-flammability, ability to remain as a liquid over a wide range of temperatures above and below room temperature, high polarity, high viscosity, and a wide electrochemical window. These properties are desirable attributes in addition to high viscosity when it comes to using RTILs as electrolyte components (salts and/or solvents) in supercapacitors.

Hereinafter, we provide some examples of several different types of anode active materials, sulfur-based cathode active materials, and ion-conducting polymers to illustrate the best mode of practicing the invention. These illustrative examples, as well as other portions of the specification and drawings, alone or in combination, are sufficient to enable one of ordinary skill in the art to practice the invention. However, these examples should not be construed as limiting the scope of the invention.

Example 1: preparation of Graphene Oxide (GO) and Reduced Graphene Oxide (RGO) nanoplates from natural graphite powder

Natural Graphite from Huadong Graphite Co (Huadong Graphite Co.) (celand china) was used as the starting material. GO is obtained by following the well-known modified helmholtz method, which involves two oxidation stages. In a typical procedure, the first oxidation is effected under the following conditions: 1100mg of graphite was placed in a 1000mL long-necked flask. Then, 20g of K was added to the flask ₂ S ₂ O ₈ 20g of P ₂ O ₅ And 400mL of concentrated H ₂ SO ₄ Aqueous solution (96%). The mixture was heated at reflux for 6 hours and then left undisturbed at room temperature for 20 hours. The graphite oxide was filtered and rinsed with copious amounts of distilled water until neutral pH. The wet cake-like material is recovered at the end of this first oxidation.

For the second oxidation process, the previously collected wet cake was placed in a container containing 69mL of concentrated H ₂ SO ₄ Aqueous solution (96%) In a long-necked flask. The flask was kept in an ice bath while slowly adding 9g KMnO ₄ . Care is taken to avoid overheating. The resulting mixture was stirred at 35 ℃ for 2 hours (the color of the sample turned dark green) and then 140mL of water was added. After 15min, the reaction mixture was purified by adding 420mL of water and 15mL of 30 wt.% H ₂ O ₂ To stop the reaction. At this stage the color of the sample turned bright yellow. To remove the metal ions, the mixture was filtered and washed with 1:10 aqueous HCl. The collected material was gently centrifuged at 2700g and rinsed with deionized water. The final product was a wet cake containing 1.4 wt.% GO (as estimated from dry extract). Subsequently, a liquid dispersion of GO platelets was obtained by mild sonication of the wet-cake material diluted in deionized water.

Surfactant stabilized RGO (RGO-BS) is obtained by diluting the wet cake in an aqueous solution of a surfactant, rather than pure water. A mixture of commercially available sodium cholate (50 wt.%) and sodium deoxycholate (50 wt.%) salts supplied by Sigma Aldrich (Sigma Aldrich) was used. The surfactant weight fraction was 0.5 wt.%. The fraction remained constant for all samples. Sonication was performed using a Benedict Soifier S-250A equipped with a 13mm step disruptor horn and a 3mm conical microtip operating at a frequency of 20 kHz. For example, 10mL of an aqueous solution containing 0.1 wt.% GO was sonicated for 10min and then centrifuged at 2700g for 30min to remove any undissolved large particles, aggregates and impurities. The chemical reduction to obtain as-received GO to produce RGO was performed by following the following procedure, which involved placing 10mL of a 0.1 wt.% GO aqueous solution in a 50mL long-necked flask. Then, 10 μ L of 35 wt.% N ₂ H ₄ (hydrazine) aqueous solution and 70mL of 28 wt.% NH ₄ An aqueous OH (ammonia) solution is added to the mixture and stabilized by a surfactant. The solution was heated to 90 ℃ and refluxed for 1 h. The pH value measured after the reaction was about 9. The color of the sample turned dark black during the reduction reaction.

In certain lithium-sulfur batteries of the invention, RGO is used as a conductive additive in either or both of the anode and cathode active materials. In selected lithium-sulfur cells, pre-lithiated RGO (e.g., RGO + lithium particles or RGO pre-deposited with a lithium coating) is also used as the anode active material.

For comparison purposes, a slurry coating and drying procedure was performed to produce a conventional electrode. An anode and a cathode, and a separator disposed between the two electrodes, were then assembled and encapsulated in an Al plastic laminate encapsulation envelope, and then injected with liquid electrolyte to form a prior art lithium battery cell.

Example 2: preparation of pristine graphene sheets (substantially 0% oxygen)

Recognizing the possibility that the high defect number in GO sheets acts to reduce the electrical conductivity of individual graphene planes, we decided to investigate whether the use of pristine graphene sheets (non-oxidized and oxygen-free, non-halogenated and halogen-free, etc.) could produce an electrically conductive additive with high electrical and thermal conductivity. Pre-lithiated pristine graphene is also used as an anode active material. Pristine graphene sheets are produced using direct sonication or a liquid phase production process.

In a typical procedure, 5 grams of graphite flakes milled to a size of about 20 μm or less are dispersed in 1,000mL of deionized water (containing 0.1% by weight of dispersant, from DuPont, Inc.; DuPont)

FSO) to obtain a suspension. An ultrasonic energy level of 85W (Branson S450 ultrasonicator) was used for puffing, separation and size reduction of graphene sheets for a period of 15 minutes to 2 hours. The resulting graphene sheets are pristine graphene that has never been oxidized and is oxygen-free and relatively defect-free. The pristine graphene is substantially free of any non-carbon elements.

Pristine graphene sheets are then incorporated into the cell as a conductive additive along with the anode active material (or cathode active material in the cathode) using both the inventive procedure of injecting the slurry into the foam cells and conventional slurry coating, drying, and lamination procedures. Both lithium ion-sulfur batteries and lithium metal-sulfur batteries were investigated.

Example 3: preparation of prelithiated graphene fluoride sheets as anode active materials for lithium ion batteries

We have used several methods to produce GF, but only one method is described herein as an example. In a typical procedure, Highly Expanded Graphite (HEG) is prepared from an intercalation compound ₂ F·xClF ₃ And (4) preparation. HEG was further fluorinated with chlorine trifluoride vapor to produce Fluorinated Highly Expanded Graphite (FHEG). Pre-cooled Teflon (Teflon) reactor is filled with 20-30mL of liquid pre-cooled ClF ₃ The reactor was closed and cooled to liquid nitrogen temperature. Then, no more than 1g of HEG was placed in a container with a container for ClF ₃ The gas enters the reactor and is located in an aperture within the reactor. Form a product with approximate formula C in 7-10 days ₂ F as a grey beige product.

Subsequently, a small amount of FHEG (approximately 0.5mg) was mixed with 20-30mL of organic solvent (methanol and ethanol respectively) and subjected to sonication (280W) for 30min, resulting in the formation of a homogeneous yellowish dispersion. After removal of the solvent, the dispersion turned brown powder. Graphene fluoride powder is mixed with surface-stabilized lithium powder in a liquid electrolyte such that pre-lithiation occurs.

Example 4: some examples of preferred salts, solvents, and polymers for forming quasi-solid polymer electrolytes

Preferred sodium metal salts include: sodium perchlorate (NaClO) ₄ ) Sodium hexafluorophosphate (NaPF) ₆ ) Sodium fluoroborate (NaBF) ₄ ) Sodium hexafluoroarsenate, potassium hexafluoroarsenate, sodium trifluoro-methanesulfonate (NaCF) ₃ SO ₃ ) And sodium bis (trifluoromethylsulfonyl) imide (NaN (CF) ₃ SO ₂ ) ₂ ). The following is a good choice of lithium salt that tends to dissolve well in the organic or ionic liquid solvent of choice: lithium fluoroborate (LiBF) ₄ ) Lithium trifluoromethanesulfonate (LiCF) ₃ SO ₃ ) Lithium bistrifluoromethylsulfonyl imide (LiN (CF) ₃ SO ₂ ) ₂ Or LITFSI), lithium bis (oxalato) borate (LiBOB), lithium oxalyldifluoroborate (LiBF) ₂ C ₂ O ₄ ) And lithium bis (per) fluoroethylsulfonylimide (LiBETI). A good electrolyte additive to help stabilize Li metal is LiNO ₃ . Particularly useful ionic liquid-based lithium salts include: lithium bis (trifluoromethanesulfonyl) imide (LiTFSI).

For aqueous electrolytes, the sodium or potassium salt is preferably selected from Na ₂ SO ₄ 、K ₂ SO ₄ A mixture thereof, NaOH, KOH, NaCl, KCl, NaF, KF, NaBr, KBr, NaI, KI, or a mixture thereof. The salt concentrations used in this study were from 0.3M to 3.0M (most often 0.5M to 2.0M).

Preferred organic liquid solvents include: ethylene Carbonate (EC), dimethyl carbonate (DMC), ethyl methyl carbonate (MEC), diethyl carbonate (DEC), Propylene Carbonate (PC), Acetonitrile (AN), Vinylene Carbonate (VC), Allyl Ethyl Carbonate (AEC), 1, 3-Dioxolane (DOL), 1, 2-Dimethoxyethane (DME), Tetraglyme (TEGDME), poly (ethylene glycol) dimethyl ether (PEGDME), diethylene glycol dibutyl ether (degbe), 2-ethoxyethyl ether (EEE), hydrofluoroethers (e.g., TPTP), sulfones, and sulfolane.

Preferred ionic liquid solvents may be selected from Room Temperature Ionic Liquids (RTILs) having cations selected from: tetraalkylammonium, dialkylimidazolium, alkylpyridinium, dialkylpyrrolidinium, or dialkylpiperidinium. The counter anion is preferably selected from BF ₄ ^- 、B(CN) ₄ ^- 、CF ₃ CO ₂ ^- 、CF ₃ SO ₃ ^- 、N(SO ₂ CF ₃ ) ₂ ^- 、N(COCF ₃ )(SO ₂ CF ₃ ) ^- Or N (SO) ₂ F) ₂ ^- . Particularly useful ionic liquid-based solvents include N-N-butyl-N-ethylpyrrolidinium bis (trifluoromethanesulfonyl) imide (BEPyTFSI), N-methyl-N-propylpiperidinium bis (trifluoromethanesulfonyl) imide (PP) ₁₃ TFSI), and N, N-diethyl-N-methyl-N- (2-methoxyethyl) ammonium bis (trifluoromethylsulfonyl) imide.

Preferred lithium ion conducting polymers or sodium ion conducting polymers include poly (ethylene oxide) (PEO, having less than 1x10 ⁶ Molecular weight in g/mol), polypropylene oxide (PPO), poly (acrylonitrile) (PAN), poly (vinylidene fluoride) -hexafluoropropylene (PVDF-HFP), and sulfonated polymers. Preference is given toThe sulfonated polymers of (a) include poly (perfluorosulfonic acid), sulfonated polytetrafluoroethylene, sulfonated polysulfone, sulfonated poly (ether ketone) (S-PEEK), and sulfonated polyvinylidene fluoride (S-PVDF).

Example 5: vapor pressures of some solvents and corresponding quasi-solid polymer electrolytes with various sodium salt molecular ratios.

Several solvents (DOL, DME, PC, AN, with or without ionic liquid-based co-solvent PP) were measured ₁₃ TFSI) in the addition of a broad range of molecular ratios along with sodium salts of PEO (e.g., sodium fluoroborate (NaBF) ₄ ) Sodium perchlorate (NaClO) ₄ ) Or sodium bis (trifluoromethanesulfonyl) imide (NaTFSI)) before and after. The vapor pressure decreases at a very high rate when the salt/polymer combination concentration exceeds 2.3M and rapidly approaches a minimum or essentially zero when the combination concentration exceeds 3.0M. At very low vapor pressures, the vapor phase of the electrolyte cannot ignite or once initiated cannot sustain the flame for longer than 3 seconds.

Example 6: some solvents and corresponding quasi-solid polymer electrolytes with 3.0M sodium or lithium salt/polymer combination concentrations had flash points and vapor pressures.

The flash point and vapor pressure of several solvents and their electrolytes with 3M Na or Li salt/polymer concentrations are presented in table 1 below. It may be noted that any liquid having a flash point below 38.7 ℃ is flammable according to OSHA (occupational safety and health administration) classification. However, to ensure safety, we have designed quasi-solid polymer electrolytes to exhibit a flash point significantly above 38.7 ℃ (by large margin, for example at least 50 ° increase and preferably above 150 ℃). The data in table 1 show that the addition of alkali metal salt/polymer combination concentrations of 3.0M is generally sufficient to meet these criteria (in many cases, 2.3M is sufficient). All of our quasi-solid polymer electrolytes are nonflammable.

Table 1: the flash point and vapor pressure of the selected solvent and its electrolyte.

^* Any liquid having a flash point below 38.7 ℃ is flammable, according to OSHA (occupational safety and health administration) classification; ^** the standard atmospheric pressure of 1 is 101,325Pa 101.325kPa 1,013.25 hPa. 133.3 Pa-0.1333 kPa

Example 7: number of alkali metal ions transferred in several electrolytes

Several types of electrolytes, such as Na in the molecular ratio of (PEO + NaTFSI salt) to lithium salt in (EMImTFSI + DME) solvent, were investigated ⁺ Ion transfer numbers, and representative results are summarized in fig. 3(a) to 3 (B). Generally, low salt concentration of Na in the electrolyte ⁺ The ion transfer number decreases with increasing concentration from 0 to 0.2-0.30. However, above the molecular ratio of x-0.2-0.30, the number of transfers increased with increasing salt concentration, indicating Na ⁺ Fundamental changes in ion transport mechanisms. A similar trend was observed for lithium ions.

When Na is present ⁺ Electrolytes with ions at low salt concentrations (e.g. x)<0.2) in the course of travel, Na ⁺ The ions may drag multiple solvated molecules with them. This cooperative migration of clusters of charged species can be further hindered if the fluid viscosity increases as more salt and polymer are dissolved in the solvent. In contrast, when an ultra-high concentration of sodium salt (having x) is present>0.2) time, Na ⁺ The number of ions may greatly exceed the available solvating molecules that might otherwise cluster the sodium ions, thereby forming polyionic complex species and slowing their diffusion process. The high Na content ⁺ The ion concentration makes it possible to have more "free Na ⁺ Ions "(unclustered), thereby providing higher Na ⁺ Number of transfer (thus providing easy Na) ⁺ Transmission). The sodium ion transport mechanism changes from a polyion complex dominated mechanism (with overall larger hydrodynamic radius) to having a large amount of free Na available ⁺ Single-ion dominated mechanism of ions (with smaller hydrodynamic radius). The observations were further identified as: a sufficient amount of Na ⁺ Ions can move rapidly through or from the quasi-solid electrolyte to make themselves readily available for interaction or reaction with the cathode (during discharge) or anode (during charge), thereby ensuring good rate performance of the sodium secondary cell. Most importantly, these highly concentrated electrolytes are non-flammable and safe. Up to now, it has been difficult to obtain combined safety, easy sodium ion transport, and electrochemical performance characteristics for all types of sodium and lithium secondary batteries.

Example 8: preparation of sulfur/carbon black (S/CB) composite particles for cathodes of lithium-sulfur batteries

The sulfur powder and CB particles were mixed (70/30 ratio) and ball milled for 2 hours to obtain S/CB particles. In this example, graphene sheets (RGO) and Carbon Nanofibers (CNF) are separately contained as conductive filaments in an electrode containing S/CB particles as a cathode active material and an electrolyte containing a lithium salt and a polymer dissolved in an organic solvent. The lithium salt used in this example includes lithium fluoroborate (LiBF) ₄ ) And the organic solvent is PC, DOL, DEC, and mixtures thereof. A wide range of conductive filament volume fractions from 0.1% to 30% were included in this study. The formation of the electrode layer is accomplished by using the following sequence of steps:

sequence 1 (S1): firstly, LiBF is firstly ₄ The salt and PEO were dissolved in a mixture of PC and DOL to form electrolytes with salt/polymer combination concentrations of 1.0M, 2.5M, and 3.5M, respectively. (in the case of concentrations of 2.3M or higher, the resulting electrolyte is no longer a liquid electrolyte. it behaves more like a solid in nature, and is therefore the term "quasi-solid") then, RGO or CNT filaments are dispersed in the electrolyte to form a filament-electrolyte suspension. Mechanical shear is used to help form a uniform dispersion. (the filament-electrolyte suspension, even at low salt concentrations of 1.0MAnd at this point, is also quite viscous). The cathode active material S/CB particles were then dispersed in the filament-electrolyte suspension to form a quasi-solid polymer electrode material.

Sequence 2 (S2): firstly, LiBF is put ₄ The salt and PEO were dissolved in a mixture of PC and DOL to form electrolytes with salt/polymer combination concentrations of 1.0M, 2.5M, and 3.5M, respectively. Then, the cathode active material S/CB particles are dispersed in the electrolyte to form an active particle-electrolyte suspension. Mechanical shear is used to help form a uniform dispersion. (the active particle-electrolyte suspension is quite viscous even at low salt concentrations of 1.0M). RGO or CNT filaments are then dispersed in the active particle-electrolyte suspension to form a quasi-solid polymer electrode material.

Sequence 3 (S3): first, a desired amount of RGO or CNT filaments are dispersed in a liquid solvent mixture (PC + DOL) that does not contain a dissolved lithium salt or polymer therein. Mechanical shearing is used to help form a uniform suspension of the conductive filaments in the solvent. Then LiBF is added ₄ Salt, PEO and S/CB particles are added to the suspension, allowing LiBF ₄ The salt and PEO were dissolved in the solvent mixture of the suspension to form electrolytes with salt/polymer combination concentrations of 1.0M, 2.5M, and 3.5M, respectively. Simultaneously or subsequently, the S/CB particles are dispersed in an electrolyte to form a deformable quasi-solid electrode material composed of active material particles and conductive filaments dispersed in a quasi-solid polymer electrolyte (not a liquid electrolyte and not a solid electrolyte). In the quasi-solid electrode material, the conductive filaments are percolated to form a 3D network of electron conducting pathways. The 3D conductive network is maintained when the electrode material is formed into an electrode of a battery.

The conductivity of the electrodes was measured using a four-point probe method. The results are summarized in fig. 5(a) and 5 (B). These data indicate that, except for the electrode manufactured by following the sequence 3(S3), the typical percolation of the 3D network of conductive filaments (CNF or RGO) for forming an electron conduction path does not occur until the volume fraction of the conductive filaments exceeds 10% -12%. In other words, the step of dispersing the conductive filaments in the liquid solvent must be performed before dissolving the lithium salt, sodium salt, or ion-conducting polymer in the liquid solvent and before dispersing the active material particles in the solvent. Such a sequence may also bring the percolation threshold down to 0.3% -2.0%, so that conductive electrodes can be produced by using very small amounts of conductive additives, and thus higher proportions of active material (and higher energy density). To date, these observations have been found to be consistent with all types of electrodes containing active material particles, conductive filaments, and electrolyte. This is a crucial and unexpected process requirement for the preparation of high performance alkali metal batteries with both high energy density and high power density.

The quasi-solid cathode, porous separator and quasi-solid anode (prepared in a similar manner but with artificial graphite particles as the anode active material) were then assembled together to form a unit cell, which was then enclosed in a protective casing (laminated aluminum plastic bag) having two terminals protruding outward to produce a battery. Cells containing liquid or polymer gel electrolytes (1M) and quasi-solid polymer electrolytes (2.5M and 3.5M) were fabricated and tested.

For comparison purposes, a slurry coating and drying procedure was performed to produce a conventional electrode. An anode and a cathode, and a separator disposed between the two electrodes, were then assembled and encapsulated in an Al plastic laminate encapsulation envelope, and then injected with liquid electrolyte to form a prior art lithium battery cell. The cell test results are summarized in example 18.

Example 9: electrochemical deposition of S on various web or paper structures for Li-S and Na-S batteries

Electrochemical deposition may be performed prior to incorporation of the cathode active material into an alkali metal-sulfur battery cell (Li-S or Na-S cell). In this method, an anode, an electrolyte, and graphene sheets (acting as a cathode layer) aggregated together are placed in an electrochemical deposition chamber. The required equipment is similar to electroplating systems well known in the art.

In a typical procedure, a metal polysulfide (M) _x S _y ) Dissolved in a solvent (e.g. DOL/DME mixed at a volume ratio of from 1:3 to 3:1Substance) to form an electrolyte solution. An amount of lithium salt may optionally be added, but this is not necessary for external electrochemical deposition. Various solvents may be used for this purpose, and there is no theoretical limit to the type of solvent that may be used; any solvent can be used as long as the metal polysulfide has some solubility in the desired solvent. A greater solubility will mean that a greater amount of sulfur can be obtained from the electrolyte solution.

The electrolyte solution is then poured into a chamber or reactor under dry and controlled atmosphere conditions (e.g., He gas or nitrogen). A metal foil may be used as the anode and a layer of porous graphene structure as the cathode; both of which are immersed in an electrolyte solution. This configuration constitutes an electrochemical deposition system. The step of electrochemically depositing the nano-sized sulfur particles or coating on the surface of the graphene sheet is preferably performed at a current density ranging from 1mA/g to 10A/g, based on the layer weight of the porous graphene structure.

The chemical reaction that occurs in the reactor can be represented by the following equation: m _x S _y →M _x S _y-z + zS (typically z ═ 1-4). Quite unexpectedly, the precipitated S preferentially nucleates and grows on the bulk of the graphene surface to form nanoscale coatings or nanoparticles. The coating thickness or particle diameter and the amount of S-coating/particles can be controlled by specific surface area, electrochemical reaction current density, temperature and time. In general, lower current densities and lower reaction temperatures result in a more uniform distribution of S and the reaction is more easily controlled. The longer reaction time results in a greater amount of S being deposited on the graphene surface, and the reaction is stopped when the sulfur source is consumed or when the desired amount of S is deposited. These S-coated paper or web structures are then comminuted into fine particles for use as cathode active materials for Li-S or Na-S cells.

Example 10: chemical reaction-induced deposition of sulfur particles on isolated graphene sheets prior to cathode layer preparation

Here, a prior art chemical deposition method was used to deposit graphene oxide sheets from isolated graphene oxide sheets (i.e. these GO sheets are not stacked into an integral body of porous graphene before S is chemically deposited on the surface of the GO sheetsStructured) to prepare an S-graphene composite. The procedure was started by mixing 0.58g Na ₂ S was added to a flask already filled with 25ml of distilled water to form Na ₂ And (5) preparing an S solution. Then, 0.72g of elemental S was suspended in Na ₂ S solution and stirred with a magnetic stirrer at room temperature for about 2 hours. As the sulfur dissolved, the color of the solution slowly changed to orange-yellow. After dissolution of the sulphur, sodium polysulphide (Na) is obtained ₂ S _x ) Solution (x ═ 4-10).

Subsequently, graphene oxide-sulfur (GO-S) composites were prepared in aqueous solution by a chemical deposition method. First, 180mg of graphite oxide was suspended in 180ml of ultra pure water and then sonicated at 50 ℃ for 5 hours to form a stable Graphene Oxide (GO) dispersion. Subsequently, Na was added in the presence of 5 wt% of cetyltrimethylammonium bromide (CTAB) as a surfactant ₂ S _x Solution addition to GO dispersion prepared above, GO/Na as prepared ₂ S _x The blended solution was sonicated for an additional 2 hours and then titrated at a rate of 30-40 drops/min into 100ml of a 2mol/L HCOOH solution and stirred for 2 hours. Finally, the precipitate was filtered and washed several times with acetone and distilled water to eliminate salts and impurities. After filtration, the precipitate was dried in a drying oven at 50 ℃ for 48 hours. The reaction may be represented by the following reaction: s _x ^2- +2H ⁺ →(x-1)S+H ₂ S。

Example 11: redox chemical reaction-induced deposition of sulfur particles on isolated graphene sheets and Activated Carbon (AC) particles prior to cathode layer preparation

In the chemical reaction-based deposition method, sodium thiosulfate (Na) is added ₂ S ₂ O ₃ ) As a sulfur source and HCl as a reactant. Preparation of GO-water or activated carbon-water suspension and then two reactants (HCl and Na) ₂ S ₂ O ₃ ) Poured into the suspension. The reaction is allowed to proceed at 25 ℃ -75 ℃ for 1-3 hours, allowing precipitates of S particles to deposit on the GO sheet surfaces or into the pores of the AC particles. The reaction may be represented by the following reaction: 2HCl + Na ₂ S ₂ O ₃ →2NaCl+S↓+SO ₂ ↑+H ₂ O。

Example 12: preparation of S/GO nanocomposites by solution deposition

Mixing and dispersing GO sheets and S in solvent (CS) ₂ ) To form a suspension. After thorough stirring, the solvent was evaporated to produce a solid nanocomposite, which was then ground to produce a nanocomposite powder. The primary sulfur particles in these nanocomposite particles have an average diameter of about 40-50 nm.

Example 13: conductive web of filaments from electrospun PAA fibrils as support layer for anode

A poly (amic acid) (PAA) precursor for spinning was prepared by copolymerizing pyromellitic dianhydride (Aldrich) and 4, 4' -oxydianiline (Aldrich) in a mixed solvent of tetrahydrofuran/methanol (THF/MeOH, 8/2 by weight). The PAA solution was spun into a web using an electrospinning apparatus. The apparatus consisted of a 15kV d.c. power supply equipped with a positively charged capillary from which the polymer solution was extruded and a negatively charged spool for collecting the fiber. Removal of solvent from PAA and imidization were performed simultaneously by stepwise heat treatment under air flow at 40 ℃ for 12h, 100 ℃ for 1h, 250 ℃ for 2h, and 350 ℃ for 1 h. The thermally cured Polyimide (PI) mesh sample was carbonized at 1,000 ℃ to obtain carbonized nanofibers having an average fibril diameter of 67 nm. Such a mesh may be used as a conductive substrate for an anode active material. We have observed that the implementation of a network of conductive nanofilaments at the anode of a Li-S cell can effectively suppress the initiation and growth of lithium dendrites that might otherwise lead to internal short circuits.

Example 14: preparation of pre-sodiated graphene fluoride sheets as anode active materials for sodium-sulfur batteries

We have used several methods to produce Graphene Fluoride (GF), but only one method is described herein as an example. In a typical procedure, Highly Expanded Graphite (HEG) is prepared from an intercalation compound ₂ F·xClF ₃ And (4) preparation. HEG was further fluorinated with chlorine trifluoride vapor to produce Fluorinated Highly Expanded Graphite (FHEG). The precooled Teflon reactor is filled with 20-30mL of liquidBulk pre-cooled ClF ₃ The reactor was closed and cooled to liquid nitrogen temperature. Then, no more than 1g of HEG was placed in a container with a container for ClF ₃ The gas enters the reactor and is located in an aperture within the reactor. Form a product with approximate formula C in 7-10 days ₂ F as a grey beige product.

Subsequently, a small amount of FHEG (approximately 0.5mg) was mixed with 20-30mL of organic solvent (methanol and ethanol respectively) and subjected to sonication (280W) for 30min, resulting in the formation of a homogeneous yellowish dispersion. After removal of the solvent, the dispersion turned brown powder. Graphene fluoride powder is mixed with sodium flakes in a liquid electrolyte such that pre-sodium modification occurs before or after injection into the pores of the anode current collector.

Example 15: graphene-reinforced nano-silicon as anode active material for lithium ion-sulfur battery

Graphene-coated Si particles are available from anchorine Energy co, Dayton, Ohio. The quasi-solid anode electrode is prepared by the following steps: pristine graphene sheets (as conductive filaments) were dispersed in a PC-DOL (50/50 ratio) mixture, followed by graphene-coated Si particles (anode active material) and 3.5M lithium hexafluorophosphate (LiPF) at 60 ℃ ₆ ) Dissolved in the mixture solvent. Then, DOL was removed to obtain a mixture containing about 5.0M LiPF in PC ₆ The quasi-solid electrolyte of (1). Since LiPF is known at room temperature ₆ The maximum solubility in PC is less than 3.0M, so this renders LiPF ₆ Is in an oversaturated state.

Example 16: graphene-enhanced tin oxide microparticles as anode active materials

Using the following procedure with SnCl ₄ ·5H ₂ Controlled hydrolysis of O with NaOH to obtain tin oxide (SnO) ₂ ) Nano-particles: SnCl ₄ ·5H ₂ O (0.95g, 2.7m-mol) and NaOH (0.212g, 5.3m-mol) were each dissolved in 50mL of distilled water. The NaOH solution was added dropwise to the tin chloride solution at a rate of 1mL/min with vigorous stirring. The solution was homogenized by sonication for 5 min. Subsequently, the resulting hydrosol was reacted with GO dispersion 3 hoursThen (c) is performed. To the mixed solution was added a few drops of 0.1M H ₂ SO ₄ To flocculate the product. The precipitated solid was collected by centrifugation, washed with water and ethanol and dried in vacuo. The dried product was heat-treated at 400 ℃ for 2h under an Ar atmosphere and used as an anode active material.

Example 17: preparation and electrochemical testing of various battery cells

For most of the anode and cathode active materials studied, we used both the inventive method and the conventional method to prepare lithium ion or lithium metal cells.

In the case of conventional processes, a typical anode composition comprises 85 wt.% active material (e.g., Si-coated graphene sheets), 7 wt.% acetylene black (Super-P), and 8 wt.% polyvinylidene fluoride binder (PVDF, 5 wt.% solids content) dissolved in N-methyl-2-pyrrolidone (NMP). After coating the slurry on the Cu foil, the electrode was dried at 120 ℃ for 2h in vacuo to remove the solvent. In the case of the process of the present invention, a binder resin is typically not needed or used, thereby saving 8% by weight (reduced amount of inactive material). A cathode layer was prepared in a similar manner (using Al foil as the cathode current collector) using conventional slurry coating and drying procedures. The anode layer, separator layer (e.g., Celgard 2400 membrane), and cathode layer are then laminated together and placed in a plastic-Al envelope. For example, the cells are then infused with 1M LiPF dissolved in a mixture of Ethylene Carbonate (EC) and diethyl carbonate (DEC) (EC-DEC, 1:1v/v) ₆ An electrolyte solution. In some cells, an ionic liquid is used as the liquid electrolyte. The cell assembly was made in an argon filled glove box.

In the method of the present invention, preferably, the quasi-solid polymer anode, the porous separator, and the quasi-solid polymer cathode are assembled in a protective housing. The bag is then sealed.

Cyclic Voltammetry (CV) measurements were performed using an Abin (Arbin) electrochemical workstation at a typical scan rate of 1 mV/s. In addition, the electrochemical performance of each cell was also evaluated by constant current charge/discharge cycling at current densities from 50mA/g to 10A/g. For long-term cycling tests, a multi-channel battery tester manufactured by LAND was used.

Example 18: representative test results

For each sample, several current densities (representing charge/discharge rates) were applied to determine the electrochemical response, allowing the energy density values and power density values required to construct a ravigneaux plot (power density versus energy density) to be calculated. The plot of the radon force (gravimetric power density versus energy density) for lithium-sulfur cells containing Li foil as the anode active material and carbon black-flow composite particles as the cathode active material is shown in fig. 6 (a). Three of the 4 data curves are for cells prepared according to embodiments of the present invention (with sequences S1, S2, and S3, respectively), while the remaining one is a cell prepared by conventional electrode paste coating (roll coating). From these data several important observations can be drawn:

the gravimetric energy density and power density of lithium ion battery cells prepared by the method of the present invention are both significantly higher than the gravimetric energy density and power density of their counterparts (denoted "conventional") prepared by conventional roll coating methods. The change in cathode thickness from 150 μm (coated on a flat solid Al foil) to 530 μm with a quasi-solid polymer electrolyte resulted in an increase in gravimetric energy density from 325Wh/kg to 413Wh/kg (S1), 425Wh/kg (S2), and 526Wh/kg (S3), respectively. Also surprisingly, cells containing the inventive quasi-solid electrodes with 3D networks of electron conducting pathways (due to percolation of the conductive filaments) gave significantly higher energy density (fig. 6(a)) and more stable cycling behavior (fig. 6 (B)).

These large differences cannot be simply attributed to the increase in electrode thickness and mass loading. The differences may be due to the significantly higher active material mass loading (not only mass loading) and higher conductivity associated with the cells of the invention, the reduced proportion of non-contributing (inactive) components relative to the active material weight/volume, and the unexpectedly better utilization of the electrode active material (most if not all of S contributes to lithium ion storage capacity due to higher conductivity and no drying pockets or dead spots in the electrode, especially under high charge/discharge rate conditions).

Fig. 7(a) shows a raleigh plot (gravimetric power density versus gravimetric energy density) for two cells, both containing graphene-loaded S-particles as cathode active material. Experimental data were obtained from Li-S battery cells prepared by the method of the invention and Li-S battery cells prepared by conventional electrode slurry coating.

These data indicate that the gravimetric energy density and power density of the battery cells prepared by the inventive process are significantly higher than their counterparts prepared by conventional processes. Also, the differences are large. The conventionally prepared cells exhibited a gravimetric energy density of 433Wh/kg, but the cells of the present invention were each given an energy density of 603Wh/kg (S3). For lithium-sulphur batteries, power densities of up to 1,887W/kg are also unprecedented. The cells of the invention also gave much more stable charge/discharge cycling behavior, as shown in fig. 7 (B).

These energy density and power density differences are primarily due to the high active material mass loading (in the anode) associated with the cells of the present invention>25mg/cm ² And in the cathode>45mg/cm ² ) And high electrode conductivity, reduced proportion of non-contributing (inactive) components relative to the weight/volume of the active material, and the ability of the inventive method to better utilize the active material (all particles are liquid electrolyte and accessible by fast ionic and electronic kinetics).

It is important to note that reporting the energy density and power density per weight of active material alone on a raleigh graph, as made by many researchers, may not give a realistic picture of the performance of an assembled supercapacitor cell. The weight of the other apparatus components must also be taken into account. These non-contributing components, including current collectors, electrolytes, separators, adhesives, connectors, and encapsulants, are inactive materials and do not contribute to charge storage. They merely add weight and bulk to the device. Therefore, it is desirable to reduce the relative proportion of the weight of the non-contributing components and increase the proportion of the active material. However, this goal has not been possible using conventional battery production methods. The present invention overcomes this long standing most serious problem in the field of lithium batteries.

In commercial lithium ion batteries having an electrode thickness of 100-200 μm, the weight proportion of anode active material (e.g., graphite or carbon) in the lithium ion battery is typically from 12% to 17%, and the weight proportion of cathode active material (for inorganic materials, such as LiMn ₂ O ₄ ) From 22% to 41%, or from 10% to 15% for organic or polymeric materials. Therefore, a factor of 3 to 4 is often used to extrapolate the energy density or power density of the device (cell) from the characteristics based solely on the weight of the active material. In most scientific papers, the reported properties are typically based on the weight of the active material alone, and the electrodes are typically very thin (<<100 μm, and most<<50 μm). The active material weight is typically from 5% to 10% of the total device weight, which means that the actual cell (device) energy density or power density can be obtained by dividing the corresponding value based on the active material weight by a factor of 10 to 20. Taking this factor into account, the properties reported in these papers do not actually look better than those of commercial batteries. Therefore, great care must be taken in reading and interpreting the performance data of batteries reported in scientific papers and patent applications.

Claims

1. An alkali-sulfur cell, comprising:

(a) a quasi-solid cathode containing from 30% to 95% by volume of a sulfur-containing cathode active material, from 5% to 40% by volume of a first electrolyte containing an alkali metal salt dissolved or dispersed in a solvent and an ionically conductive polymer, and from 0.01% to 30% by volume of a conductive additive, wherein the sulfur-containing cathode active material comprises sulfur, a metal-sulfur compound, a sulfur-carbon composite, a sulfur-graphene composite, a sulfur-graphite composite, an organosulfur compound, a sulfur-polymer composite, or a combination thereof, and wherein the conductive additive containing conductive filaments forms a 3D network of electron conducting pathways, such that the quasi-solid cathode is such that the quasi-solid cathode contains from 30% to 95% by volume of the first electrolyte, and from 0.01% to 30% by volume of the conductive additiveThe cathode has a diameter of from 10 ^-6 A conductivity of S/cm to 300S/cm;

(b) an anode; and

(c) an ion-conducting membrane or porous separator disposed between the anode and the quasi-solid cathode; wherein the quasi-solid cathode has a thickness of not less than 200 μm.

2. The alkali metal-sulfur cell of claim 1, wherein the anode comprises a quasi-solid anode comprising from 1.0% to 95% by volume of an anode active material, from 5% to 40% by volume of a second electrolyte comprising an alkali metal salt dissolved or dispersed in a solvent and an ionically conductive polymer, and from 0.01% to 30% by volume of a conductive additive, wherein the conductive additive comprising electrically conductive filaments forms a 3D network of electron conducting pathways, such that the quasi-solid anode has from 10 ^-6 A conductivity of S/cm to 300S/cm.

3. The alkali metal-sulfur cell of claim 1, wherein the first electrolyte comprises a quasi-solid polymer electrolyte comprising an ionically conductive polymer selected from the group consisting of: having a density of less than 1x10 ⁶ Poly (ethylene oxide) (PEO), polypropylene oxide (PPO), poly (acrylonitrile) (PAN), poly (methyl methacrylate) (PMMA), poly (vinylidene fluoride) (PVDF), poly bis (methoxyethoxyethanol-phosphazene), polyvinyl chloride, polydimethylsiloxane, poly (vinylidene fluoride) -hexafluoropropylene (PVDF-HFP), sulfonated derivatives thereof, sulfonated polymers, or combinations thereof in g/mol.

4. The alkali metal-sulfur cell of claim 2, wherein the first electrolyte or the second electrolyte comprises a quasi-solid polymer electrolyte comprising an ion conducting polymer selected from the group consisting of: having a density of less than 1x10 ⁶ Poly (ethylene oxide) (PEO), polypropylene oxide (PPO), poly (acrylonitrile) (PAN), poly (methyl methacrylate) (PMMA), poly (vinylidene fluoride) (PVDF), poly (methoxyethoxyethanol-phosphazene), polyvinyl chloride, polydimethylsiloxane, poly (ethylene oxide) (PEO), poly (propylene oxide) (PPO), poly (acrylonitrile) (PAN), poly (methyl methacrylate) (PMMA), poly (vinylidene fluoride) (PVDF), poly (bismethoxyethoxyethanol-phosphazene), poly (vinyl chloride) (PVDC),Poly (vinylidene fluoride) -hexafluoropropylene (PVDF-HFP), sulfonated derivatives thereof, sulfonated polymers, or combinations thereof.

5. The alkali metal-sulfur cell of claim 1, wherein the ion conducting polymer is selected from the group consisting of: poly (perfluorosulfonic acid), sulfonated polytetrafluoroethylene, sulfonated perfluoroalkoxy derivatives of polytetrafluoroethylene, sulfonated polysulfone, sulfonated poly (ether ketone), sulfonated poly (ether ketone), sulfonated polystyrene, sulfonated polyimide, sulfonated styrene-butadiene copolymers, sulfonated Polychlorotrifluoroethylene (PCTFE), sulfonated perfluoroethylene-propylene copolymers (FEP), sulfonated ethylene-chlorotrifluoroethylene copolymers (ECTFE), sulfonated polyvinylidene fluoride (PVDF), sulfonated copolymers of polyvinylidene fluoride with hexafluoropropylene and tetrafluoroethylene, sulfonated copolymers of Ethylene and Tetrafluoroethylene (ETFE), sulfonated Polybenzimidazole (PBI), chemical derivatives, copolymers, blends, and combinations thereof.

6. The alkali metal-sulfur cell of claim 2, wherein the ion conducting polymer is selected from the group consisting of: poly (perfluorosulfonic acid), sulfonated polytetrafluoroethylene, sulfonated perfluoroalkoxy derivatives of polytetrafluoroethylene, sulfonated polysulfone, sulfonated poly (ether ketone), sulfonated poly (ether ketone), sulfonated polystyrene, sulfonated polyimide, sulfonated styrene-butadiene copolymers, sulfonated Polychlorotrifluoroethylene (PCTFE), sulfonated perfluoroethylene-propylene copolymers (FEP), sulfonated ethylene-chlorotrifluoroethylene copolymers (ECTFE), sulfonated polyvinylidene fluoride (PVDF), sulfonated copolymers of polyvinylidene fluoride with hexafluoropropylene and tetrafluoroethylene, sulfonated copolymers of Ethylene and Tetrafluoroethylene (ETFE), sulfonated Polybenzimidazole (PBI), chemical derivatives, copolymers, blends, and combinations thereof.

7. The alkali metal-sulfur cell of claim 1, wherein the electrically conductive filaments are selected from carbon fibers, carbon nanotubes, needle coke, carbon whiskers, electrically conductive polymer fibers, electrically conductive material coated fibers, metal wires, combinations thereof, or combinations thereof with non-filament electrically conductive particles.

8. The alkali-sulfur cell of claim 1, wherein the ionically conductive polymer does not form a matrix in the quasi-solid cathode.

9. The alkali-sulfur cell of claim 1, wherein the quasi-solid cathode is maintained from 10 ^-3 A conductivity of S/cm to 10S/cm.

10. The alkali-sulfur cell of claim 1, wherein the quasi-solid cathode contains from 0.1 to 20% by volume of a conductive additive.

11. The alkali-sulfur cell of claim 1, wherein the quasi-solid cathode contains from 1% to 10% by volume of a conductive additive.

12. The alkali-sulfur cell of claim 1, wherein the amount of sulfur-containing cathode active material comprises from 40% to 90% by volume of the quasi-solid cathode.

13. The alkali-sulfur cell of claim 1, wherein the amount of sulfur-containing cathode active material comprises from 50% to 85% by volume of the quasi-solid cathode.

14. The alkali-sulfur cell of claim 1, wherein the first electrolyte is in a supersaturated state.

15. The alkali-sulfur cell of claim 2, wherein the first electrolyte or the second electrolyte is in a supersaturated state.

16. The alkali metal-sulfur cell of claim 1, wherein the solvent is selected from water, an organic solvent, an ionic liquid, or a mixture of an organic solvent and an ionic liquid.

17. The alkali-sulfur cell of claim 2, wherein the first electrolyte or the second electrolyte comprises a solvent selected from the group consisting of: water, an organic solvent, an ionic liquid, or a mixture of an organic solvent and an ionic liquid.

18. The alkali-sulfur cell of claim 1, wherein the anode comprises an anode active material selected from the group consisting of:

(a) particles, films, or foils of lithium metal or lithium metal alloys;

(b) natural graphite particles, artificial graphite particles, mesocarbon microbeads (MCMB), carbon particles, needle coke, carbon nanotubes, and carbon fibers;

(c) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), nickel (Ni), cobalt (Co), manganese (Mn), titanium (Ti), iron (Fe), and cadmium (Cd);

(d) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, or Cd with other elements, wherein the alloys or compounds are stoichiometric or non-stoichiometric;

(e) oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ni, Co, Ti, Mn, or Cd, and mixtures or composites thereof;

(f) a prelithiated version thereof;

(g) pre-lithiated graphene sheets; and

combinations thereof.

19. The alkali-sulfur cell of claim 18, wherein the pre-lithiated graphene sheets are selected from a pre-lithiated version of pristine graphene, graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, boron-doped graphene, nitrogen-doped graphene, chemically functionalized graphene, physically or chemically activated or etched versions thereof, or combinations thereof.

20. The alkali-sulfur cell of claim 1, wherein the alkali-sulfur cell is a sodium metal-sulfur cell or a sodium ion-sulfur cell and the anode comprises an anode active material comprising sodium metal or an alkali intercalation compound selected from: petroleum coke, amorphous carbon, activated carbon, hard carbon, soft carbon, template carbon, hollow carbon nanowire, hollow carbon sphere, titanate, NaTi ₂ (PO ₄ ) ₃ 、Na ₂ Ti ₃ O ₇ 、Na ₂ C ₈ H ₄ O ₄ 、Na ₂ TP、Na _x TiO ₂ Materials based on carboxylic acid salts, C ₈ H ₆ O ₄ 、C ₈ H ₅ NaO ₄ 、C ₈ Na ₂ F ₄ O ₄ 、C ₁₀ H ₂ Na ₄ O ₈ 、C ₁₄ H ₄ O ₆ 、C ₁₄ H ₄ Na ₄ O ₈ Or a combination thereof, wherein x is 0.2 to 1.0.

21. The alkali-sulfur cell of claim 2, wherein the alkali-sulfur cell is a sodium-sulfur cell or a sodium ion-sulfur cell and the anode comprises an anode active material selected from the group consisting of:

a) particles, foils, or films of sodium metal or sodium metal alloys;

b) natural graphite particles, artificial graphite particles, mesocarbon microbeads (MCMB), carbon particles, needle coke, carbon nanotubes, and carbon fibers;

c) sodium-doped silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), cobalt (Co), nickel (Ni), manganese (Mn), cadmium (Cd), and mixtures thereof;

d) sodium-containing alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Co, Ni, Mn, Cd, and mixtures thereof;

e) sodium-containing oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides, or antimonides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Fe, Ti, Co, Ni, Mn, Cd, and mixtures or composites thereof;

f) a sodium salt;

g) graphene sheets pre-loaded with sodium ions; and combinations thereof.

22. The alkali metal-sulfur cell of claim 1, wherein the cathode active material is supported by a functional or nanostructured material selected from the group consisting of:

A) nanostructured or porous disordered carbon materials selected from particles of soft carbon, hard carbon, polymeric or carbonized resins, mesophase carbon, coke, carbonized pitch, carbon black, activated carbon, nano-cellular carbon foam or partially graphitized carbon;

B) a nano-graphene platelet selected from a single layer graphene sheet or a multi-layer graphene platelet;

C) carbon nanotubes selected from single-walled carbon nanotubes or multi-walled carbon nanotubes;

D) carbon nanofibers, nanowires, metal oxide nanowires or fibers, conductive polymer nanofibers, or a combination thereof;

E) carbonyl-containing organic or polymeric molecules;

F) functional materials containing carbonyl, carboxyl or amine groups that reversibly capture sulfur;

and combinations thereof.

23. The alkali-sulfur cell of claim 1, wherein the first electrolyte comprises an organic solvent selected from the group consisting of: 1, 3-Dioxolane (DOL), 1, 2-Dimethoxyethane (DME), Tetraglyme (TEGDME), poly (ethylene glycol) dimethylether (PEGDME), diethylene glycol dibutyl ether (degbe), 2-ethoxyethyl ether (EEE), sulfone, sulfolane, Ethylene Carbonate (EC), dimethyl carbonate (DMC), Methyl Ethyl Carbonate (MEC), diethyl carbonate (DEC), ethyl propionate, methyl propionate, Propylene Carbonate (PC), gamma-butyrolactone (gamma-BL), Acetonitrile (AN), Ethyl Acetate (EA), Propyl Formate (PF), Methyl Formate (MF), toluene, xylene, Methyl Acetate (MA), fluoroethylene carbonate (FEC), Vinylene Carbonate (VC), Allyl Ethyl Carbonate (AEC), hydrofluoroether, and combinations thereof.

24. The alkali metal-sulfur cell of claim 1, wherein the first electrolyte comprises an alkali metal salt selected from the group consisting of: lithium perchlorate (LiClO) ₄ ) Lithium hexafluorophosphate (LiPF) ₆ ) Lithium fluoroborate (LiBF) ₄ ) Lithium hexafluoroarsenate (LiAsF) ₆ ) Lithium trifluoromethanesulfonate (LiCF) ₃ SO ₃ ) Lithium bistrifluoromethylsulfonyl imide (LiN (CF) ₃ SO ₂ ) ₂ ) Lithium bis (oxalato) borate (LiBOB), lithium oxalyldifluoroborate (LiBF) ₂ C ₂ O ₄ ) Lithium nitrate (LiNO) ₃ ) Lithium fluoroalkylphosphate (LiPF3 (CF) ₂ CF ₃ ) ₃ ) Lithium bis (perfluoroethylsulfonimide) (LiBETI), sodium perchlorate (NaClO) ₄ ) Potassium perchlorate (KClO) ₄ ) Sodium hexafluorophosphate (NaPF) ₆ ) Potassium hexafluorophosphate (KPF) ₆ ) Sodium fluoroborate (NaBF) ₄ ) Potassium fluoroborate (KBF) ₄ ) Sodium hexafluoroarsenate, potassium hexafluoroarsenate, sodium trifluoromethanesulfonate (NaCF) ₃ SO ₃ ) Potassium trifluoromethanesulfonate (KCF) ₃ SO ₃ ) Bis (trifluoromethyl) sulfonimide sodium (NaN (CF) ₃ SO ₂ ) ₂ ) Sodium trifluoromethanesulfonylimide (NaTFSI), potassium bistrifluoromethylsulfonylimide (KN (CF) ₃ SO ₂ ) ₂ ) Or a combination thereof.

25. The alkali metal-sulfur cell of claim 1, wherein the first electrolyte comprises an ionic liquid solvent selected from room temperature ionic liquids having a cation selected from the group consisting of: tetraalkylammonium, di-, tri-, or tetra-alkylimidazolium, alkylpyridinium, dialkylpyrrolidinium, dialkylpiperidinium, tetraalkylphosphonium, trialkylsulfonium, or combinations thereof.

26. The alkali metal-sulfur cell of claim 25, wherein the ionic liquid solvent is selected from room temperature ionic liquids having an anion selected from: BF (BF) generator ₄ ^- 、B(CN) ₄ ^- 、CH ₃ BF ₃ ^- 、CH ₂ CHBF ₃ ^- 、CF ₃ BF ₃ ^- 、C ₂ F ₅ BF ₃ ^- 、n-C ₃ F ₇ BF ₃ ^- 、n-C ₄ F ₉ BF ₃ ^- 、PF ₆ ^- 、CF ₃ CO ₂ ^- 、CF ₃ SO ₃ ^- 、N(SO ₂ CF ₃ ) ₂ ^- 、N(COCF ₃ )(SO ₂ CF ₃ ) ^- 、N(SO ₂ F) ₂ ^- 、N(CN) ₂ ^- 、C(CN) ₃ ^- 、SCN ^- 、SeCN ^- 、CuCl ₂ ^- 、AlCl ₄ ^- 、F(HF) _2.3 ^- Or a combination thereof.

27. The alkali-sulfur cell of claim 1, wherein the cathode active material comprises greater than 15mg/cm ² Electrode active material mass loading.

28. The alkali-sulfur cell of claim 2, wherein the anode active material composition is greater than 20mg/cm ² Electrode active material mass loading.

29. The alkali-sulfur cell of claim 1, wherein the cathode active material composition is greater than 30mg/cm ² Electrode active material mass loading.

30. The alkali-sulfur cell of claim 7, wherein the carbon fiber is a graphite fiber.

31. The alkali-sulfur cell of claim 7, wherein the carbon fiber is a carbon nanofiber.

32. The alkali-sulfur cell of claim 30, wherein the graphite fibers are graphite nanofibers.

33. The alkali metal-sulfur cell of claim 7, wherein the metal wire is a metal nanowire.

34. The alkali metal-sulfur cell of claim 18, wherein the carbon fiber in (b) is a graphite fiber.

35. The alkali metal-sulfur cell of claim 18, wherein the carbon fibers in (b) are carbon nanofibers.

36. The alkali-sulfur cell of claim 21, wherein the carbon fiber in b) is a graphite fiber.

37. The alkali-sulfur cell of claim 21, wherein the carbon fibers in b) are carbon nanofibers.

38. An alkali-sulfur cell, comprising:

A) a quasi-solid anode comprising from 1.0% to 95% by volume of an anode active material, from 5% to 40% by volume of an electrolyte comprising an alkali metal salt and an ionically conductive polymer dissolved or dispersed in a solvent, and from 0.01% to 30% by volume of a conductive additive, wherein the conductive additive comprising conductive filaments forms a 3D network of electron conducting pathways, whereby the quasi-solid anode has from 10 ^-6 A conductivity of S/cm to 300S/cm;

B) a cathode comprising a cathode active material selected from the group consisting of: sulfur, a metal-sulfur compound, a sulfur-carbon composite, a sulfur-graphene composite, a sulfur-graphite composite, an organosulfur compound, or a sulfur-polymer composite, wherein the cathode contains from 30 to 95% by volume of a cathode active material, from 5 to 40% by volume of an electrolyte containing an alkali metal salt dissolved or dispersed in a solvent and an ion-conducting polymer, and from 0.01 to 30% by volume of a conductive additive; and

C) an ion-conducting membrane or porous separator disposed between the quasi-solid anode and the cathode.

39. The alkali metal-sulfur cell of claim 38, wherein the electrolyte is a quasi-solid polymer electrolyte comprising an ion conducting polymer selected from the group consisting of: having a density of less than 1x10 ⁶ Poly (ethylene oxide) (PEO), polypropylene oxide (PPO), poly (acrylonitrile) (PAN), poly (methyl methacrylate) (PMMA), poly (vinylidene fluoride) (PVDF), poly bis (methoxyethoxyethanol-phosphazene), polyvinyl chloride, polydimethylsiloxane, poly (vinylidene fluoride) -hexafluoropropylene (PVDF-HFP), sulfonated derivatives thereof, sulfonated polymers, or combinations thereof in g/mol.

40. The alkali metal-sulfur cell of claim 38, wherein the ion conducting polymer is selected from the group consisting of: poly (perfluorosulfonic acid), sulfonated polytetrafluoroethylene, sulfonated perfluoroalkoxy derivatives of polytetrafluoroethylene, sulfonated polysulfone, sulfonated poly (ether ketone), sulfonated poly (ether ketone), sulfonated polystyrene, sulfonated polyimide, sulfonated styrene-butadiene copolymers, sulfonated Polychlorotrifluoroethylene (PCTFE), sulfonated perfluoroethylene-propylene copolymers (FEP), sulfonated ethylene-chlorotrifluoroethylene copolymers (ECTFE), sulfonated polyvinylidene fluoride (PVDF), sulfonated copolymers of polyvinylidene fluoride with hexafluoropropylene and tetrafluoroethylene, sulfonated copolymers of Ethylene and Tetrafluoroethylene (ETFE), sulfonated Polybenzimidazole (PBI), chemical derivatives, copolymers, blends, and combinations thereof.

41. The alkali metal-sulfur cell of claim 38, wherein the ionically conductive polymer does not form a matrix in the quasi-solid anode.

42. A method of making an alkali metal-sulfur cell with a quasi-solid electrode, the method comprising:

(a) combining an amount of a cathode active material, an amount of an electrolyte, and a conductive additive to form a deformable and conductive cathode material, wherein the cathode active material comprises a sulfur-containing material selected from the group consisting of: sulfur, a metal-sulfur compound, a sulfur-carbon composite, a sulfur-graphene composite, a sulfur-graphite composite, an organosulfur compound, a sulfur-polymer composite, or a combination thereof, and wherein the conductive additive containing conductive filaments forms a 3D network of electron conducting pathways and the electrolyte contains an alkali metal salt and an ion conducting polymer dissolved or dispersed in a solvent;

(b) forming the cathode material into a quasi-solid cathode, wherein the forming comprises deforming the cathode material into an electrode shape without interrupting the 3D network of electron-conducting pathways, thereby causing the quasi-solid cathode to remain no less than 10 ^-6 Conductivity of S/cm;

(c) forming an anode; and is provided with

(d) Forming an alkali metal-sulfur cell by combining the quasi-solid cathode and the anode, wherein the quasi-solid cathode contains from 30% to 95% by volume of the cathode active material, 5% to 40% by volume of the electrolyte, and 0.01% to 30% by volume of the conductive additive.

43. The method of claim 42, wherein the electrolyte comprises a quasi-solid polymer electrolyte comprising an ion conducting polymer selected from the group consisting of: having a refractive index of less than 1x10 ⁶ Poly (ethylene oxide) (PEO), polypropylene oxide (PPO), poly (acrylonitrile) (PAN), poly (methyl methacrylate) (PMMA), poly (vinylidene fluoride) (PVDF), poly bis (methoxyethoxyethanol-phosphazene), polyvinyl chloride, polydimethylsiloxane, poly (vinylidene fluoride) -hexafluoropropylene (PVDF-HFP), sulfonated derivatives thereof, sulfonated polymers, or combinations thereof in g/mol.

44. The method of claim 42, wherein the ion conducting polymer is selected from the group consisting of: poly (perfluorosulfonic acid), sulfonated polytetrafluoroethylene, sulfonated perfluoroalkoxy derivatives of polytetrafluoroethylene, sulfonated polysulfone, sulfonated poly (ether ketone), sulfonated poly (ether ketone), sulfonated polystyrene, sulfonated polyimide, sulfonated styrene-butadiene copolymers, sulfonated polychloro-trifluoroethylene (PCTFE), sulfonated perfluoroethylene-propylene copolymers (FEP), sulfonated ethylene-chlorotrifluoroethylene copolymers (ECTFE), sulfonated polyvinylidene fluoride (PVDF), sulfonated copolymers of polyvinylidene fluoride with hexafluoropropylene and tetrafluoroethylene, sulfonated copolymers of Ethylene and Tetrafluoroethylene (ETFE), sulfonated Polybenzimidazole (PBI), chemical derivatives, copolymers, blends, and combinations thereof.

45. The method of claim 42, wherein the conductive filament is selected from carbon fibers, carbon nanotubes, needle coke, carbon whiskers, conductive polymer fibers, conductive material coated fibers, metal wires, combinations thereof, or combinations thereof with non-filament conductive particles.

46. The method of claim 45, wherein the carbon fibers are graphite fibers.

47. The method of claim 45, wherein the carbon fibers are carbon nanofibers.

48. The method of claim 46, wherein the graphite fibers are graphite nanofibers.

49. The method of claim 45, wherein the metal lines are metal nanowires.

50. The method of claim 42, wherein the ionically conductive polymer does not form a matrix in the quasi-solid cathode.

51. The method of claim 42, wherein the quasi-solid cathode is maintained from 10 ^-3 A conductivity of S/cm to 10S/cm.

52. The method of claim 42, wherein the quasi-solid cathode contains from 0.1% to 20% by volume of a conductive additive.

53. The method of claim 42, wherein the quasi-solid cathode contains from 1% to 10% by volume of a conductive additive.

54. The method of claim 42, wherein the amount of cathode active material is from 40% to 90% by volume of the cathode material.

55. The method of claim 42, wherein the active material is present in an amount of 50% to 85% by volume of the cathode material.

56. The method of claim 42, wherein step (a) comprises dispersing the conductive filaments in a liquid solvent to form a homogeneous suspension, followed by adding the cathode active material in the suspension and followed by dissolving the alkali metal salt and the ionically conductive polymer in the liquid solvent of the suspension.

57. The method of claim 42, wherein steps (a) and (b) comprise dissolving a lithium or sodium salt and the polymer in a liquid solvent to form an electrolyte having a first salt/polymer concentration and subsequently removing a portion of the liquid solvent to increase the salt/polymer concentration to obtain a quasi-solid polymer electrolyte having a second salt/polymer concentration higher than the first salt/polymer concentration and higher than 2.5M.

58. The method of claim 57, wherein the removing does not cause precipitation or crystallization of the salt or the polymer, and the electrolyte is in a supersaturated state.

59. The method of claim 57, wherein the liquid solvent comprises a mixture of at least a first liquid solvent and a second liquid solvent and the first liquid solvent is more volatile than the second liquid solvent, and wherein the removing a portion of the liquid solvent comprises removing the first liquid solvent.

60. The method of claim 42, wherein the step of forming the anode comprises (A) combining an amount of anode active material, an amount of electrolyte, and a conductive additive to form a deformable and conductive anode material, wherein the conductive additive comprising conductive filaments forms a 3D network of electron conducting pathways, and the electrolyte comprises an alkali metal salt and an ionically conductive polymer dissolved or dispersed in a solvent; and (B) forming the deformable and electrically conductive anode material into a quasi-solid anode, wherein the forming comprises deforming the deformable and electrically conductive anode material into an electrode shape without interrupting the 3D network of electron conduction pathways, thereby causing the anode to remain no less than 10a ^-6 Conductivity of S/cm.

61. The method of claim 42, wherein the solvent is selected from water, an organic solvent, an ionic liquid, or a mixture of an organic solvent and an ionic liquid.

62. The method of claim 42, wherein the alkali metal-sulfur cell is a lithium ion-sulfur cell and the anode comprises an anode active material selected from the group consisting of:

(a) particles of lithium metal or lithium metal alloy;

(d) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al or Cd with other elements, wherein the alloys or compounds are stoichiometric or non-stoichiometric;

(f) a prelithiated version thereof;

(g) pre-lithiated graphene sheets; and

a combination thereof.

63. The method of claim 62, wherein said carbon fibers in (b) are graphite fibers.

64. The method of claim 62, wherein the carbon fibers in (b) are carbon nanofibers.

65. The method of claim 62, wherein the pre-lithiated graphene sheets are selected from pre-lithiated versions of pristine graphene, graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, boron-doped graphene, nitrogen-doped graphene, chemically functionalized graphene, physically or chemically activated or etched versions thereof, or combinations thereof.

66. The method of claim 42, wherein the alkali metal-sulfur cell is a sodium ion-sulfur cell and the anode comprises an anode active material comprising an alkali intercalation compound selected from: petroleum coke, carbon black, amorphous carbon, activated carbon, hard carbon, soft carbon, template carbon, hollow carbon nanowire, hollow carbon sphere, titanate, NaTi ₂ (PO ₄ ) ₃ 、Na ₂ Ti ₃ O ₇ 、Na ₂ C ₈ H ₄ O ₄ 、Na ₂ TP、Na _x TiO ₂ Materials based on carboxylic acid salts, C ₈ H ₆ O ₄ 、C ₈ H ₅ NaO ₄ 、C ₈ Na ₂ F ₄ O ₄ 、C ₁₀ H ₂ Na ₄ O ₈ 、C ₁₄ H ₄ O ₆ 、C ₁₄ H ₄ Na ₄ O ₈ Or a combination thereof, wherein x is 0.2 to 1.0.

67. The method of claim 42, wherein the alkali metal-sulfur cell is a sodium ion-sulfur cell and the active material is an anode active material selected from the group consisting of:

a) particles of sodium metal or sodium metal alloy;

f) a sodium salt;

g) graphene sheets pre-loaded with sodium ions; and combinations thereof.

68. The method of claim 67, wherein said carbon fibers in b) are graphite fibers.

69. The method of claim 67, wherein the carbon fibers in b) are carbon nanofibers.

70. The method of claim 42, wherein the cathode active material composition is greater than 15mg/cm ² Electrode active material mass loading.

71. The method of claim 42, wherein the cathode active material composition is greater than 25mg/cm ² Electrode active material mass loading.

72. The method of claim 42, wherein the cathode active material composition is greater than 45mg/cm ² Electrode active material mass loading.