US2011256450A1PendingUtilityA1

Electrochemical cells comprising porous structures comprising sulfur

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Assignee: SION POWER CORPPriority: Aug 28, 2009Filed: Mar 11, 2011Published: Oct 20, 2011
Est. expiryAug 28, 2029(~3.1 yrs left)· nominal 20-yr term from priority
Inventors:Christopher T. S. CampbellChariclea Scordilis-Kelley
H01M 4/5815H01M 4/0402H01M 4/382H01M 2010/4292H01G 11/06H01M 2004/021H01M 4/60H01M 4/38Y10T29/49115H01M 4/80H01M 4/602H01M 4/364H01M 4/136H01M 4/668H01M 4/62Y02E60/13H01M 4/583H01M 4/64Y10T29/49108Y02E60/10Y02T10/70Y02P70/50
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Claims

Abstract

The present invention relates to the use of porous structures comprising sulfur in electrochemical cells. Such materials may be useful, for example, in forming one or more electrodes in an electrochemical cell. For example, the systems and methods described herein may comprise the use of an electrode comprising a conductive porous support structure and a plurality of particles comprising sulfur (e.g., as an active species) substantially contained within the pores of the support structure.

Claims

exact text as granted — not AI-modified
1 . An electrode for use in an electrochemical cell, comprising:
 a porous support structure formed by assembling a plurality of particles in contact with each other, the porous support structure comprising a plurality of pores; and   an electrode active material comprising sulfur substantially contained within the pores of the porous support structure, wherein:
 each particle of the plurality of particles has a maximum cross-sectional dimension; 
 at least about 50% of the particles have maximum cross-sectional dimensions of between about 0.5 microns and about 20 microns; 
 each pore of the plurality of pores has a pore volume, and the plurality of pores has a total pore volume defined by the sum of each of the individual pore volumes; 
 at least about 50% of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns; and 
 the porosity of the electrode is at least about 30%. 
   
     
     
         2 . An electrode for use in an electrochemical cell, comprising:
 a porous support structure formed by assembling a plurality of particles in contact with each other, the porous support structure comprising a plurality of pores; and   an electrode active material comprising sulfur substantially contained within the pores of the porous support structure, wherein
 each particle of the plurality of particles has a maximum cross-sectional dimension; 
 at least about 50% of the particles have maximum cross-sectional dimensions of between about 0.5 microns and about 20 microns; 
 the plurality of pores of the porous support structure together defines a total pore volume, and at least about 50% of the total pore volume is defined by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns; and 
 the porosity of the electrode is at least about 30%. 
   
     
     
         3 . A method of making an electrode for use in an electrochemical cell, comprising:
 providing a plurality of particles, wherein each particle each particle of the plurality of particles has a maximum cross-sectional dimension, and at least about 50% of the particles have maximum cross-sectional dimensions of between about 0.5 microns and about 20 microns;   forming a porous support structure using the particles, wherein:
 the agglomerated structure comprises a plurality of pores, 
 each pore of the plurality of pores has a pore volume, 
 the plurality of pores has a total pore volume defined by the sum of each of the individual pore volumes, and 
 at least about 50% of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns; and 
   providing an electrode active material comprising sulfur substantially within the pores of the porous support structure.   
     
     
         4 . An electrode as in  claim 1 , wherein at least about 70% of the particles have maximum cross-sectional dimensions of between about 0.5 microns and about 20 microns. 
     
     
         5 . An electrode as in  claim 1 , wherein at least about 80% of the particles have maximum cross-sectional dimensions of between about 0.5 microns and about 20 microns. 
     
     
         6 . An electrode as in  claim 1 , wherein at least about 90% of the particles have maximum cross-sectional dimensions of between about 0.5 microns and about 20 microns. 
     
     
         7 . An electrode as in  claim 1 , wherein at least about 95% of the particles have maximum cross-sectional dimensions of between about 0.5 microns and about 20 microns. 
     
     
         8 . An electrode as in  claim 1 , wherein at least about 99% of the particles have maximum cross-sectional dimensions of between about 0.5 microns and about 20 microns. 
     
     
         9 . An electrode as in  claim 1 , wherein substantially all of the particles have maximum cross-sectional dimensions of between about 0.5 microns and about 20 microns. 
     
     
         10 . An electrode as in  claim 1 , wherein at least about 50% of the particles have maximum cross-sectional dimensions of between about 3 microns and about 5 microns. 
     
     
         11 . An electrode as in  claim 1 , wherein at least about 70% of the particles have maximum cross-sectional dimensions of between about 3 microns and about 5 microns. 
     
     
         12 . An electrode as in  claim 1 , wherein at least about 80% of the particles have maximum cross-sectional dimensions of between about 3 microns and about 5 microns. 
     
     
         13 . An electrode as in  claim 1 , wherein at least about 90% of the particles have maximum cross-sectional dimensions of between about 3 microns and about 5 microns. 
     
     
         14 . An electrode as in  claim 1 , wherein at least about 95% of the particles have maximum cross-sectional dimensions of between about 3 microns and about 5 microns. 
     
     
         15 . An electrode as in  claim 1 , wherein at least about 99% of the particles have maximum cross-sectional dimensions of between about 3 microns and about 5 microns. 
     
     
         16 . An electrode as in  claim 1 , wherein substantially all of the particles have maximum cross-sectional dimensions of between about 3 microns and about 5 microns. 
     
     
         17 . An electrode as in  claim 1 , wherein at least about 70% of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns. 
     
     
         18 . An electrode as in  claim 1 , wherein at least about 80% of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns. 
     
     
         19 . An electrode as in  claim 1 , wherein at least about 90% of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns. 
     
     
         20 . An electrode as in  claim 1 , wherein at least about 95% of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns. 
     
     
         21 . An electrode as in  claim 1 , wherein at least about 99% of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns. 
     
     
         22 . An electrode as in  claim 1 , wherein substantially all of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns. 
     
     
         23 . An electrode as in  claim 1 , wherein at least about 50% of the total pore volume is occupied by pores having cross-sectional diameters of between about 1 micron and about 10 microns. 
     
     
         24 . An electrode as in  claim 1 , wherein at least about 70% of the total pore volume is occupied by pores having cross-sectional diameters of between about 1 micron and about 10 microns. 
     
     
         25 . An electrode as in  claim 1 , wherein at least about 80% of the total pore volume is occupied by pores having cross-sectional diameters of between about 1 micron and about 10 microns. 
     
     
         26 . An electrode as in  claim 1 , wherein at least about 90% of the total pore volume is occupied by pores having cross-sectional diameters of between about 1 micron and about 10 microns. 
     
     
         27 . An electrode as in  claim 1 , wherein at least about 95% of the total pore volume is occupied by pores having cross-sectional diameters of between about 1 micron and about 10 microns. 
     
     
         28 . An electrode as in  claim 1 , wherein at least about 99% of the total pore volume is occupied by pores having cross-sectional diameters of between about 1 micron and about 10 microns. 
     
     
         29 . An electrode as in  claim 1 , wherein substantially all of the total pore volume is occupied by pores having cross-sectional diameters of between about 1 micron and about 10 microns. 
     
     
         30 . An electrode as in  claim 1 , wherein at least about 50% of the total pore volume is occupied by pores having cross-sectional diameters of between about 3 microns and about 5 microns. 
     
     
         31 . An electrode as in  claim 1 , wherein at least about 70% of the total pore volume is occupied by pores having cross-sectional diameters of between about 3 microns and about 5 microns. 
     
     
         32 . An electrode as in  claim 1 , wherein at least about 80% of the total pore volume is occupied by pores having cross-sectional diameters of between about 3 microns and about 5 microns. 
     
     
         33 . An electrode as in  claim 1 , wherein at least about 90% of the total pore volume is occupied by pores having cross-sectional diameters of between about 3 microns and about 5 microns. 
     
     
         34 . An electrode as in  claim 1 , wherein at least about 95% of the total pore volume is occupied by pores having cross-sectional diameters of between about 3 microns and about 5 microns. 
     
     
         35 . An electrode as in  claim 1 , wherein at least about 99% of the total pore volume is occupied by pores having cross-sectional diameters of between about 3 microns and about 5 microns. 
     
     
         36 . An electrode as in  claim 1 , wherein substantially all of the total pore volume is occupied by pores having cross-sectional diameters of between about 3 microns and about 5 microns. 
     
     
         37 . An electrode as in  claim 1 , wherein the porosity of the electrode is at least about 40%. 
     
     
         38 . An electrode as in  claim 1 , wherein the porosity of the electrode is at least about 50%. 
     
     
         39 . An electrode as in  claim 1 , wherein the porosity of the electrode is at least about 60%. 
     
     
         40 . An electrode as in  claim 1 , wherein the porosity of the electrode is at least about 70%. 
     
     
         41 . An electrode as in  claim 1 , wherein the porosity of the electrode is at least about 80%. 
     
     
         42 . An electrode as in  claim 1 , wherein the porosity of the electrode is at least about 90%. 
     
     
         43 . An electrode as in  claim 1 , wherein the porous support structure comprises at least one of carbon, a metal, a polymer, a ceramic, and a semiconductor. 
     
     
         44 . An electrode as in  claim 1 , wherein the porous support structure comprises carbon. 
     
     
         45 . An electrode as in  claim 44 , wherein the carbon comprises graphene. 
     
     
         46 . An electrode as in  claim 44 , wherein the carbon comprises graphite. 
     
     
         47 . An electrode as in  claim 44 , wherein the carbon comprises carbon black. 
     
     
         48 . An electrode as in  claim 44 , wherein the carbon comprises acetylene black. 
     
     
         49 . An electrode as in  claim 44 , wherein the carbon comprises carbon fibers. 
     
     
         50 . An electrode as in  claim 44 , wherein the carbon comprises carbon nanofibers. 
     
     
         51 . An electrode as in  claim 44 , wherein the carbon comprises hallow carbon tubes. 
     
     
         52 . An electrode as in  claim 44 , wherein the carbon comprises carbon filaments. 
     
     
         53 . An electrode as in  claim 1 , wherein the porous support structure comprises a metal. 
     
     
         54 . An electrode as in  claim 53 , wherein the metal comprises aluminum. 
     
     
         55 . An electrode as in  claim 53 , wherein the metal comprises titanium. 
     
     
         56 . An electrode as in  claim 1 , wherein the porous support structure comprises silicon dioxide. 
     
     
         57 . An electrode as in  claim 1 , wherein the sulfur comprises at least one of elemental sulfur, polymeric sulfur, inorganic sulfides, inorganic polysulfides, organic sulfides, organic polysulfides, and sulfur organic compounds. 
     
     
         58 . An electrode as in  claim 1 , wherein the sulfur comprises elemental sulfur. 
     
     
         59 . An electrode as in  claim 1 , wherein the electrode comprises at least about 20 wt % sulfur. 
     
     
         60 . An electrode as in  claim 1 , wherein the electrode active material occupies at least about 10% of the accessible pore volume of the porous support structure. 
     
     
         61 . An electrode as in  claim 1 , wherein the electrode has a void volume of at least about 1 cm 3  per gram of sulfur. 
     
     
         62 . An electrode as in  claim 1 , wherein an electrochemical cell comprising the electrode is capable of utilizing at least about 65% of the total sulfur in the cell through at least 1 charge and discharge cycles subsequent to a first charge and discharge cycle, wherein 100% utilization corresponds to 1672 mAh per gram of sulfur in the electrode. 
     
     
         63 . An electrode as in  claim 1 , wherein an electrochemical cell comprising the electrode is capable of utilizing at least about 65% of the total sulfur in the cell through at least 10 charge and discharge cycles subsequent to a first charge and discharge cycle, wherein 100% utilization corresponds to 1672 mAh per gram of sulfur in the electrode. 
     
     
         64 . An electrode as in  claim 1 , wherein an electrochemical cell comprising the electrode is capable of achieving a current density of at least about 100 mA per gram of sulfur in the electrode during at least one charge and discharge cycle subsequent to a first charge and discharge cycle. 
     
     
         65 . An electrode as in  claim 1 , wherein an electrochemical cell comprising the electrode is capable of achieving a current density of at least about 100 mA per gram of sulfur in the electrode during at least 10 charge and discharge cycles subsequent to a first charge and discharge cycle. 
     
     
         66 . An electrode as in  claim 1 , wherein the porous support structure comprises a porous continuous structure. 
     
     
         67 . An electrode as in  claim 1 , wherein the maximum cross-sectional dimension of the porous continuous structure within the electrode is at least about 50% of the maximum cross sectional dimension of the electrode. 
     
     
         68 . An electrode as in  claim 1 , wherein:
 the electrode has a surface,   at least about 50% of the area of the surface of the electrode defines a uniform area with a first average concentration of sulfur, and   any continuous area that covers about 10% of the uniform area of the surface of the electrode includes a second average concentration of sulfur that varies by less than about 25% relative to the first average concentration of sulfur across the uniform area.   
     
     
         69 . An electrode as in  claim 1 , wherein:
 the electrode has a surface,   at least about 50% of the area of the surface of the electrode defines a first, continuous area of essentially uniform sulfur distribution, and the first area has a first average concentration of sulfur, and   any continuous area that covers about 10% of the first, continuous area of the surface of the electrode includes a second average concentration of sulfur that varies by less than about 25% relative to the first average concentration of sulfur across the first, continuous area.   
     
     
         70 . An electrode as in  claim 1 , wherein:
 the electrode has a thickness and a cross-section substantially perpendicular to the thickness,   at least about 50% of the cross-section defines a uniform area with a first average concentration of sulfur, and   any continuous area that covers about 10% of the uniform area of the cross-section includes a second average concentration of sulfur that varies by less than about 25% relative to the first average concentration of sulfur across the uniform area.   
     
     
         71 . An electrode as in  claim 1 , wherein:
 the electrode has a thickness and a cross-section substantially perpendicular to the thickness,   at least about 50% of the area of the cross-section defines a first, continuous area of essentially uniform sulfur distribution, and the first area has a first average concentration of sulfur, and   any continuous area that covers about 10% of the first, continuous area of the cross-section includes a second average concentration of sulfur that varies by less than about 25% relative to the first average concentration of sulfur across the first, continuous area.   
     
     
         72 . An electrode as in  claim 1 , wherein the electrode contains less than about 20 wt % binder. 
     
     
         73 . An electrode as in  claim 1 , wherein the ratio of the average maximum cross-sectional dimension of particles of electrode active material within the porous support structure to the average cross-sectional diameter of the pores within the porous support structure is between about 0.001:1 and about 1:1. 
     
     
         74 . An electrode as in  claim 1 , wherein the porous support structure comprises an electrically conductive material. 
     
     
         75 . An electrode as in  claim 74 , wherein an electrically conductive material is deposited on the porous support structure.

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