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dryingandsubsequenthandling,andevenwitharesin electrolyte(injectedintoacelafterthecelismade)to permeate through the electrode and,as such,a thick elec trodewouldmeanmanydrypocketsorspotsthatarenot20 wetted by the electrolyte. This would imply a poor utiliza tion of the active materials. The instant invention solves theselong-standing,criticalyimportantisuesasociated with alkalimetalbatteries. conductive porous rod having pores and a second mixture of a second electrode active material and a secondelectrolyte,whereinsaidsecondmixtureresides insaidporesofsaidsecondporousrod;whereinsaid separator-protectedfirstelectrodeandsaidsecondelec trodearecombined orinterlacedtogethertoform a braidorayarnhavingatwistorspiralelectrodeand said first electrode and second electrode contains an US 9,905,856 B1 ofanalkalimetalbatery(includingalkalimetal-sulfur)is ofthefoamedcurentcolectorattheanodeandamore manufacturing-limitedandonecanotproduceelectrodesof uniformlocalelectricfieldinsuchafoamedstructurethat goodstructuralintegritythatexcedcertainthickneslevel drivesthealkalimetaldepositionduringrepeatedre-charge inarealindustrialmanufacturingenvironment(e.g.arol- procedures. to-rolslurrycoatingfacility).Theconventionalbattery5 Weclaim: electrodedesignisbasedoncoatinganelectrodelayerona 1.Arope-shapedalkalimetal-sulfurbaterywhereinsaid flatmetalcurentcolector,whichhasseveralmajorprob- alkalimetalisselectedfromLi,Na,oracombination lems:(a)AthickcoatingonCufoilorAlfoilrequiresalong thereof;saidbaterycomprising: (a)afirstelectrodecomprisingafirstelectricalyconduc tiveporousrodhavingporesandafirstmixtureofa first electrode active material and a first electrolyte, binderproportionashighas15-20%tohopefulyimprove whereinsaidfirstmixtureresidesinsaidporesofsaid theelectrodeintegritythisproblemremainsamajorlimiting firstporousrod; factor.Thus,suchanindustrypracticeofrol-coatingof (b)aporousseparatorwrapingaroundorencasingsaid sluryonasolidflatcurentcolectordoesnotalowforhigh 15 firstelectrodetoform aseparator-protectedfirstelec activematerialmassloadings.(c)Athickelectrodeprepared trode; bycoating,drying,andcompresionmakesitdificultfor (c)asecondelectrodecomprisingasecondelectricaly dryingtime(requiringaheatingzone30-10meterslong). (b)Thickelectrodestendtogetdelaminatedorcrackedupon 10 Shown inFIG.9arethecel-levelgravimetric (Wh/kg) 25 andvolumetricenergydensities(Wh/L)ofLiion-Scels anodeandacathode;and (Pre-lithiatedgraphiteanode+RGO foam-suportedScath (d) a protective casing or sheath wrapping around or ode)plotedovertheachievablecathodethicknesrangeof encasingsaidbraidoryarn; theS/RGO cathodepreparedviatheconventionalmethod without delamination and cracking and those by the pres- 30 wherein eitherthefirstelectrodeorthesecondelectrode isacathodecontainingsulfurorasulfurcompoundas acathodeactivematerialandsaidbateryhasarope entlyinventedcableconstructionmethod. Theelectrodescanbefabricateduptoathicknesof shapehavingalength-to-diameterorlength-to-thick 10-20um usingtheconventionalslurycoatingproces. nesaspectrationolesthan5. However,incontrast,thereisno theoreticallimiton the 2.Thealkalimetal-sulfurbateryofclaim 1,whereinsaid electrodethicknessordiameterthatcanbeachievedwith the 35 sulfurcompound isselected from organo-sulfur,polymer presentlyinventedmethod.Typicaly,thepracticalelectrode sulfur,carbon-sulfur,metalsulfide,S-Sb,S-Bi,S-Se, thicknesisfrom 10um to1000um,moretypicalyfrom 10um to80um,andmosttypicalyfrom 20um to60 um . Thesedatafurtherconfirmthesurprisingefectivenesof40sulfurbondedtoporewalsofsaidfirstorsecondporous thepresentlyinventedmethodinproducingultra-thick rod,sulfurbondedtoorconfinedbyacarbonorgraphite lithiumorsodiumbateryelectrodesnotpreviouslyachiev material,sulfurbondedtoorconfinedbyapolymer,sulfur able.Theseultra-thickelectrodesinsodiummetalbateries carboncompound,metalsulfideMS,whereinxisan leadtoexceptionalyhighsulfurcathodeactivematerial integerfrom1to3andyisanintegerfrom1to10,andM massloading,typicallysignificantly>15mg/cm (more45isametalelementselectedfromLi,Na,K,Mg,Ca,a typicaly>20mg/cm2,furthertypicaly>30mg/cm2,often >40mg/cm2,andeven>50mg/cm2).Thesehighactive materialmassloadingshavenotbenposibletoobtainwith transitionmetal,ametalfromgroups13to17oftheperiodic table,oracombinationthereof. 4.Thealkalimetal-sulfurbateryofclaim 1,whereinsaid conventionalalkalimetal-sulfurbateriesmadebytheslury firstelectrodeisanegativeelectrodeoranodeandsaid coatingprocesses.Thesehighactivematerialmassloadings 50 secondelectrodeisapositiveelectrodeorcathode. ledtoexceptionalyhighgravimetricandvolumetricenergy 5.Thealkalimetal-sulfurbateryofclaim 1,whereinsaid densitiesthatotherwisehavenotbenpreviouslyachieved secondelectrodeisanegativeelectrodeoranodeandsaid giventhesamebaterysystem. firstelectrodeisapositiveelectrodeorcathode. Dendriteisuescommonly asociatedwith LiandNa 6.Thealkalimetal-sulfurbateryofclaim 1,whereinsaid metalsecondarycelsarealso resolvedbyusingthepres-5 cathodeactivematerialissupportedbyafunctionalmaterial entlyinventedfoamedcurrentcolectorstrategy.Hundreds ornano-structuredmaterialselectedfromthegroupconsist ofcelshavebeeninvestigatedandthosecelshavinga ingof: foamedanodecurentcolectorwerenotfoundtofaildueto i.anano-structuredorporousdisorderedcarbonmaterial dendritepenetrationthroughtheseparator.SEM examina tionofsamplesfrom presentlyinventedsodium andpotas-60 sium celsconfirmsthatthere-depositedalkalimetalsur facesonporewalsinaporousanodecurentcolector appeartobesmooth anduniform,exhibitingnosignofsharp metaldepositortre-likefeaturesasoftenobservedwith correspondingcelshavingasolidcurentcolector(Cufoil)65 graphenesheetormulti-layergrapheneplatelet; attheanode.Thismightbeduetoareducedexchange i.acarbonnanotubeselectedfrom asingle-walled curentdensityasociatedwithahighspecificsurfacearea carbonnanotubeormulti-walledcarbonnanotube; S-Temixture,oracombinationthereof. 3.Thealkalimetal-sulfurbateryofclaim 1,whereinsaid cathode active material contains a material selected from selected from particlesofasoftcarbon,hard carbon, polymericcarbonorcarbonizedresin,meso-phasecar bon,coke,carbonizedpitch,carbonblack,activated carbon,nano-celularcarbonfoam orpartialygraphi tizedcarbon; i.ananographeneplateletselectedfrom asingle-layerPDF Image | FLEXIBLE AND SHAPE-CONFORMAL ROPE-SHAPE ALKALI METAL-SULFUR BATTERIES
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