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US 9,905,856 B1 energydensityisgreaterthan60Wh/L,furtherpreferably asecondelectrolyte,whereinthesecondmixtureresidesin greaterthan80Wh/L,andmostpreferablygreaterthan theporesofthesecondporousrodorfilament;whereinthe alkalimetal-sulfurcelthatexhibitsahighcathodespecific 5 havingatwistorspiralelectrodeandthefirstelectrodeand capacity,higherthan1,200mAh/gbasedonthesulfur secondelectrodecontainsananodeandacathode;and(d)a weight,orhigherthan1,0mAh/gbasedonthecathode protectivecasingorsheathwrapingaroundorencasingthe compositeweight(includingsulfur,conductingaditiveor braidoryarn;whereineitherthefirstelectrodeorthesecond substrate,andbinderweightscombined,butexcludingthe electrodeisacathodecontainingsulfurorasulfurcom weightofcathodecurrentcollector).Thespecificcapacityis 10 poundasacathodeactivematerialandthebatteryhasarope preferablyhigherthan1,400mAh/gbasedonthesulfur shapehavingalength-to-diameterorlength-to-thicknes weightaloneorhigherthan1,200mAh/gbasedonthe aspectrationolesthan5. cathodecompositeweight.Thismustbeaccompaniedbya Inthisbaterystructure,eitherthefirstelectrodeorthe highspecificenergy,goodresistancetodendriteformation, secondelectrodeisacathodeandeitherthefirstelectrode and alongandstablecyclelife. 15 activematerialorthesecondelectrodeactivematerialisa Aditionaly,thickelectrodesarealsomechanicalyrigid, cathodeactivematerialthatcontainssulfurorasulfur notflexible,notbendable,andnotconformaltoadesired compound(e.g.organo-sulfur,polymer-sulfur,carbon-sul shape.Assuch,forconventionalalkalimetal-sulfurbater- fur,metalsulfide,S Sb,S-Bi,S-Se,S—Temixture ies,highvolumetric/gravimetricenergydensityand materials,etc.)asacathodeactivematerial.Thefirstelec mechanicalflexibilityappeartobemutuallyexclusive. 20trolytecanbethesameordiferentfromthesecondelec Withthegrowingdemandformorecompactandportable trolyte. energystoragesystems,thereiskeeninterestoincreasethe Incertain prefered embodiments,thecathodeactive utilizationofthevolumeofthebateries.Novelelectrode materialisselectedfrom(A)sulfurbondedtoporewalsof materialsanddesignsthatenablehighvolumetriccapacities theporousrodorfilament,(B)sulfurbondedtoorconfined and high mass loadings are essentialto achieving improved 25 by a carbon or graphite material, (C ) sulfur bonded to or celvolumetriccapacitiesandenergydensitiesforalkali confinedbyapolymer,(D)sulfur-carboncompound,(E) metal-sulfurbatteries. metalsulfideM S„,whereinxisanintegerfrom 1to3and Therefore,thereisclearandurgentneedforalkalimetal- yisanintegerfrom1to10,andMisametalelement sulfurbateriesthathavehighactivematerialmassloading selectedfromLi,Na,K,Mg,Ca,atransitionmetal,ametal (higharealdensity),activematerialswithhighaparent30fromgroups13to17oftheperiodictable,oracombination density(hightapdensity),highelectrodethickneswithout thereof. significantlydecreasingtheelectronandiontransportrates Inthisalkalimetal-sulfurbatery,thefirstelectrodecanbe (e.g.withoutahighelectrontransportresistanceorlong anegativeelectrode(oranode)andthesecondelectrodea lithiumorsodiumiondifusionpath),highvolumetric positiveelectrode(orcathode);orviceversa.Multiple capacity,andhighvolumetricenergydensity.Theseatri-35 filamentaryanodesmaybecombinedwithoneormultiple butesmustbeachieved,alongwithimprovedflexibility, filamentarycathodestoformabraidortwistyarn.Multiple shapeconformability,andsafetyoftheresultingbatery. filamentarycathodesmaybecombinedwithoneormultiple filamentaryanodestoform abraidortwistyarn. SUMMARY OF THEINVENTION Theelectricalyconductiveporousrod(orfilament)inthe 40 firstor second electrodemay contain aporous foam selected Thepresentinventionprovidesarope-shapedalkali fromametalfoam,metalweb,metalfibermat,metal metal-sulfurbaterywhereinthealkalimetalisselectedfrom nanowiremat,conductivepolymerfibermat,conductive Li,Na,oracombinationthereof.Theelectrodesinthe polymerfoam,conductivepolymer-coatedfiberfoam,car bateryareeachofarodorfilamentaryshapeandporous, bonfoam,graphitefoam,carbonaerogel,grapheneaerogel, containingamixtureofanactivematerialandanelectrolyte 45 carbon xerogel, graphene foam,graphene oxide foam, pre-impregnatedintopores.Thefilamentaryelectrodeis reducedgrapheneoxidefoam,carbonfiberfoam,graphite encasedinaporousseparator,whichispermeabletoionsof fiberfoam,exfoliatedgraphitefoam,oracombination Li+,Na+,orK+.Multipleelectrodefilamentsarebraidedor thereof.Thesefoamscanbemadeintohighlydeformable interlacedintoabraidortwistyarn,whichisencasedina andconformablestructures.Theelectricalyconductive protectivesheath.Thebatteryhasaropeshapehavinga50porousrodmay containacarbongraphitefiber,fibertow, length-to-diameterorlength-to-thicknesaspectrationoles fiberyarn,fiberbraid,orfiberknitstructurethatisporous. than5,preferablynolesthan10,morepreferablygreater Theaforementionedfoam structurescanbereadilymade than15,furthermorepreferablygreaterthan20,stilmore intoaporositylevel >50%,more typicaly >70%,more preferablygreaterthan50.Thereisnotheoreticallimiton typicalyandpreferably>80%,stilmoretypicalyand theaspectratio.However,thecablelengthcanbemileslong5preferably >90%,andmostpreferably >95% (graphene and,withacablediameterof5mmandalengthof>10km, aerogelcanexceda9%porositylevel).Theskeleton apracticalaspectratio limitmay be >10%. structure(porewalls)inthesefoamsformsa3D networkof Insomeembodiments,thebatterycomprises:(a)afirst electron-conductingpathwayswhiletheporescanaccom electrodecomprisingafirstelectricalyconductiveporous modatealargeproportionofanelectrodeactivematerial rodorfilamenthavingporesandafirstmixtureofafirst60 (anodeactivematerialintheanodeorcathodeactivemate electrodeactivematerialandafirstelectrolyte,whereinthe rialinthecathode)withoutusinganyconductiveadditiveor firstmixtureresidesintheporesofthefirstporousrodor abinderresin. filament;(b)aporousseparatorwrappingaroundorencas- Thefilamentaryorrod-likefoam canhaveacros-section ingthefirstelectrodetoformaseparator-protectedfirst thatiscircular,eliptic,rectangular,square,hexagon,hol electrode;(c)asecondelectrodecomprisingasecondelec-65 low,oriregularinshape.Thereisnoparticularrestriction tricalyconductiveporousrodorfilamenthavingporesand onthecros-sectionalshapeofthefoamstructure.The asecondmixtureofasecondelectrodeactivematerialand bateryhasacableshapethathasalengthandadiameteror 1,000Wh/L. Anotherobjectofthepresentinventionistoprovidean arecombinedorinterlacedtogethertoformabraidorayarn separator-protected first electrode and the second electrodePDF Image | FLEXIBLE AND SHAPE-CONFORMAL ROPE-SHAPE ALKALI METAL-SULFUR BATTERIES
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