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III.B.6 Development of High-Energy Lithium Sulfur Cells (PSU) Christopher Johnson, DOE Program Manager Subcontractor: Pennsylvania State University Donghai Wang, Program Manager 328 Reber Building University Park, PA 16802 Phone: (814) 863-1287; Fax: (814) 863-4848 E-mail: dwang@psu.edu Subcontractors: EC Power, Subcontractor: Johnson Controls, Argonne National Lab Start Date: September 30, 2011 Projected End Date: January 15, 2015 Objectives Develop a novel nanocomposite sulfur cathode for lithium-sulfur batteries with high energy density, efficiency, and cycle life. Develop a novel Li-rich composite anode for Li-S batteries to improve cell cycle life. Develop novel electrolyte and electrolyte additives for Li-S batteries to improve cell efficiency, stability, and safety. Design, fabricate, test, and optimize the design of Li-S batteries using the above new technologies to maximize energy, power, abuse tolerance, and other favorable traits. Perform thermal testing of the developed Li-S cells and materials. Technical Barriers Polysulfide dissolution and shuttling, combined with degradation of the lithium metal anode and formation of an unstable SEI layer, can severely limit cell lifespan. High sulfur loading in the cathode is required for achieving a high energy density; however, high loading often leads to parts of the electrode becoming inaccessible to electrolyte, thereby decreasing energy density and cycle life. Cathodes must have high active material loading – however, the low density of sulfur and common composite materials (porous carbon, etc) make thin, crack-free, high- loading electrodes difficult to achieve. Electrolyte modifications that decrease polysulfide solubility or improve SEI layer stability often come at the cost of increased impedance and other issues. Technical Targets Scale up active material production to the 1 kg level. Design pouch cells with energy density > 400 Wh/l, 80% capacity retention after 200 cycles at C/2. Nail penetration testing at USABC EUCAR Level 3. Accomplishments Scaled up production of PSU-3 cathode material to the 0.5 kg level. Optimized coating techniques for high- loading, double-sided electrodes. Characterized and tested several new electrolytes for high-loading sulfur cathodes, along with additives for those electrolytes, enabling lower stable cycling, high capacity, high efficiency, and decreased self-discharge. Thoroughly characterized and optimized different Li powder based anodes. Optimized and tested design parameters for Li- S pouch cells. Fabricated and tested pouch cells with PSU-3 cathodes, Li foil and Li powder based anodes, different electrolytes, demonstrating above- design-capacity performance with LiP anodes, and identified possible failure mechanisms. Introduction DOE goals require the development of a high- energy, high-power, high-efficiency, long-lasting, low- cost, and safe battery. This project aims to meet these goals by using the extremely promising lithium-sulfur battery chemistry. The S cathode has a theoretical capacity of 1,672 mAh/g with a nominal voltage of 2V. In addition, sulfur does not experience any significant size change during lithium insertion/extraction, making it very stable in principle. The price of lithium-sulfur’s great promise is the major challenges with which it is replete. Lithium Energy Storage R&D 82 FY 2013 Annual Progress ReportPDF Image | Advanced Battery Development
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