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US 9,905,856 B1 thicknesandanaspectratio(length/thicknesorlength wire,conductivecarbon/graphitefiber,orconductivepoly diameterratio)greaterthan10,preferablygreaterthan15, merfiberthatisembeddedin,connectedto,orintegralwith morepreferablygreaterthan20,furtherpreferablygreater thefirstelectrode.Incertainpreferedembodiments,theat than30,evenmorepreferablygreaterthan50or10.There leastonemetalicwire,conductivecarbon/graphitefiber,or isnorestrictiononthelengthordiameter(orthicknes)of5 conductivepolymerfiberrunsapproximatelyfromthefirst thecablebattery.Thethicknessordiameteristypicalyand endtothesecondend.Thiswireorfiberpreferablyis preferablyfrom10nmto10cm,morepreferablyand protrudedoutofthefirstendorsecondendtobecomea typically from 1um to 1cm ,andmost typically from 10 um terminal tab for connecting to an electronic device or to1mm.Thelengthcanrunfrom1umtotensofmetersor externalcircuitorload. evenhundredsofmeters(ifsodesired). 10 Alternativelyoraditionaly,therope-shapedbateryhas Incertainembodiments,theinventionincludesarope- afirstendandasecondendandthesecondelectrode shapedalkalimetal-sulfurbaterywhereinthealkalimetalis containsasecondterminalconectorcomprisingatleastone selectedfromLi,Na,oracombinationthereof.Thebatery metalicwire,conductivecarbon/graphitefiber,orconduc isesentialycomposedof:(a)afirstelectrodecomprisinga tivepolymerfiberthatisembeddedin,connectedto,or firstelectricalyconductiverodandafirstmixtureofafirst 15 integralwiththesecondelectrode.Incertainembodiments, electrodeactivematerialandafirstelectrolyte,whereinthe atleastonemetalicwire,conductivecarbon/graphitefiber, firstmixtureisdepositedonorinthefirstrod;(b)aporous orconductivepolymerfiberrunsaproximatelyfromsaid separatorwrappingaroundorencasingthefirstelectrodeto firstendtosaidsecondend.Thiswireorfiberpreferablyis formaseparator-protectedfirstelectrode;(c)asecond protrudedoutofthefirstendorsecondendtobecomea electrode comprising a second electricaly conductive 20 terminal tab for connecting to an electronic device or porousrodhavingporesandasecondmixtureofasecond externalcircuitorload. electrodeactivematerialandasecondelectrolyte,wherein Insomeembodiments,thefirstelectrodeorsecondelec thesecondmixtureresidesintheporesofthesecondporous trodecontainsparticles,foil,orcoatingofLi,Na,K,ora rod;whereintheseparator-protectedfirstelectrodeandthe combinationthereofasanelectrodeactivematerial. secondelectrodeareinterlacedorcombinedinatwistor25 Incertainembodimentsoftheinvention,thealkalimetal spiralmannertoformabraidoryarn;and(d)aprotective bateryisalithium-ionbateryandthefirstorsecond casingorsheathwrappingaroundorencasingthebraidor electrodeactivematerialisselectedfromthegroupconsist yarn.Eitherthefirstelectrodeorthesecondelectrodeisa ingof:(a)Particlesofnaturalgraphite,artificialgraphite, cathodeandeitherthefirstelectrodeactivematerialorthe meso-carbonmicrobeads(MCMB),andcarbon;(b)Silicon secondelectrodeactivematerialisacathodeactivematerial 30 (Si),germanium (Ge),tin (Sn),lead (Pb),antimony (Sb), selectedpreferablyfromsulfurbondedtoporewallsofthe bismuth(Bi),zinc(Zn),aluminum(Al),nickel(Ni),cobalt porousrod,sulfurbondedtoorconfinedbyacarbonor (Co),manganese(Mn),titanium(Ti),iron(Fe),andcad graphitematerial,sulfurbondedtoorconfinedbyapolymer, mium(Cd);(c)AlloysorintermetalliccompoundsofSi,Ge, sulfur-carboncompound,metalsulfideMS„,whereinxis Sn,Pb,Sb,Bi,Zn,Al,orCdwithotherelements,wherein anintegerfrom 1to3andyisanintegerfrom 1to10,and 35saidalloysorcompoundsarestoichiometricornon-stoi MisametalelementselectedfromLi,Na,K,Mg,Ca,a chiometric;(d)Oxides,carbides,nitrides,sulfides,phosphi transitionmetal,ametalfromgroups13to17oftheperiodic des,selenides,andteluridesofSi,Ge,Sn,Pb,Sb,Bi,Zn, table,oracombinationthereof.Thebateryhasaropeshape A1,Fe,Ni,Co,Ti,Mn,orCd,andtheirmixturesor havingalength-to-diameterorlength-to-thicknesaspect composites;(e)Pre-lithiatedversionsthereof;(f)Pre-lithi rationolesthan5. 40 atedgrapheneshets;andcombinationsthereof. In some embodiments,the invention includes arope Thepre-lithiated graphene shetsmay be selected from shapedalkalimetal-sulfurbaterywhereinthealkalimetalis pre-lithiatedversionsofpristinegraphene,grapheneoxide, selectedfromLi,Na,oracombinationthereof.Thebatery reducedgrapheneoxide,graphenefluoride,graphenechlo isesentialycomposedof(a)afirstelectrodecomprisingan ride,graphenebromide,grapheneiodide,hydrogenatedgra electricalyconductiveporousrodhavingatleast50%by 45 phene,nitrogenatedgraphene,boron-dopedgraphene,nitro volumeofporesandafirstmixtureofafirstelectrodeactive gen-dopedgraphene,chemicallyfunctionalizedgraphene,a materialandafirstelectrolyteresidingintheporesofthe physicalyorchemicallyactivatedoretchedversionthereof, porousrod;(b)aporousseparatorwrappingaroundthefirst oracombinationthereof. electrode;(c)asecondelectrodecomprisinganelectricaly Insomeembodiments,thealkalimetal-sulfurbateryisa conductiverodhavingasecondmixtureofasecondelec-50 sodium-ionsulfurbateryandthefirstorsecondelectrode trodeactivematerialandasecondelectrolytedeposited activematerialcontainsanalkaliintercalationcompound thereonortherein;whereintheseparator-protectedfirst selectedfrompetroleumcoke,carbonblack,amorphous electrodeandthesecondelectrodeareinterlacedorcom- carbon,activatedcarbon,hardcarbon,softcarbon,tem binedinatwistorspiralmannertoformabraidoryarn;and platedcarbon,hollowcarbonnanowires,hollowcarbon (d)aprotectivecasingorsheathwrappingaroundorencas-5 sphere,titanates,NaTiz(PO4)3,Na Tiz07,Na2C2H404, ingthebraidoryarn.Eitherthefirstelectrodeorthesecond NaTP,NaTi0,(x=0.2to1.0),Na2C2H404,carboxylate electrodeisacathodeandeitherthefirstelectrodeactive based materials, CHNa,02, CH,O4, CHNa04, materialorthesecondelectrodeactivematerialisacathode CgNa2F404,C1oH_Na_08,C14H406,C14H_Na_0s,ora activematerialselectedfromsulfurorasulfurcompound combinationthereof. Thesulfurcompoundmaybeselectedfromorgano-sulfur,60 Insomeembodiments,thealkalimetal-sulfurbateryisa polymer-sulfur,carbon-sulfur,metalsulfide,S-Sb,S-Bi, sodium-ionsulfurbateryandthefirstorsecondelectrode S-Se,S-Temixture,oracombinationthereof.Thebatery activematerialcontainsanalkaliintercalationcompound hasacableshapehavingalength-to-diameterorlength-to selectedfromthefolowinggroupsofmaterials:(a)Sodium thicknesaspectrationolesthan5. orpotassium-dopedsilicon(Si),germanium (Ge),tin(Sn), Incertainembodiments,therope-shapedbateryhasa65 lead(Pb),antimony(Sb),bismuth(Bi),zinc(Zn),aluminum firstendandasecondendandthefirstelectrodecontainsa (Al),titanium(Ti),cobalt(Co),nickel(Ni),manganese firstterminalconectorcomprisingatleastonemetalic (Mn),cadmium(Cd),andmixturesthereof;(b)Sodium-orPDF Image | FLEXIBLE AND SHAPE-CONFORMAL ROPE-SHAPE ALKALI METAL-SULFUR BATTERIES
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