# US 10,319,988 B2 · Electrode fabrication methods and associated systems and articles

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- Number: US 10,319,988 B2
- Document ID: US10319988B2
- Status: Granted
- Kind: B2
- Application number: 15/623,604
- Filed: 2017-06-15
- Published: 2017-10-05
- Granted: 2019-06-11
- Earliest claimed: 2014-05-01
- Assignees: Sion Power Corporation
- Applicants: Sion Power Corporation
- Inventors: Tracy Earl Kelley; Savannah V. Burnside-Joubert; Ruediger Schmidt; Holger Schneider; Klaus Leitner; Joern Kulisch
- Web page: https://patentgrep.com/patent/US10319988B2

## CPC

- H01M 4/136: Electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
- H01M 4/0404: {by coating on electrode collectors}
- H01M 4/043: {involving compressing or compaction}
- H01M 4/134: Electrodes based on metals, Si or alloys
- H01M 4/139: Processes of manufacture
- H01M 4/38: of elements or alloys
- H01M 4/382: {Lithium (H01M4/405 takes precedence)}
- H01M 4/5815: {Sulfides}
- H01M 4/622: {being polymers}
- H01M 4/625: {Carbon or graphite}
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H01M 10/052: Li-accumulators
- H01M 2004/021: {Physical characteristics, e.g. porosity, surface area}
- Y02E 60/10: Energy storage using batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

Sulfur-based electrodes, and associated systems and methods for their fabrication, are generally described. Certain embodiments relate to sulfur-based electrodes with smooth external surfaces. According to some embodiments, relatively large forces can be applied to compositions from which the sulfur-based electrodes are made during the fabrication process. In some such embodiments, the compositions can maintain relatively high porosities, even after the relatively large forces have been applied to them. Methods in which liquids are employed during the electrode fabrication process are also described.

## Claims

### Claim 1

An electrode, comprising:
an external geometric active surface comprising:
a particulate electronically conductive material;
an electrode active material; and
a binder;
wherein:
the electrode has a porosity of at least about 40%, and
the external geometric active surface of the electrode has a root mean square surface roughness of at least about 0.1 micrometers and less than or equal to about 15 micrometers over a geometric surface area of at least about 10,000 square micrometers.

### Claim 2 (depends on 1)

The electrode of claim 1, wherein the particulate electronically conductive material is porous.

### Claim 3 (depends on 1)

The electrode of claim 1, wherein the particulate electronically conductive material comprises carbon.

### Claim 4 (depends on 3)

The electrode of claim 3, wherein the particulate electronically conductive material comprises carbon black.

### Claim 5 (depends on 1)

The electrode of claim 1, wherein the particulate electronically conductive material has a bulk electronic resistivity of less than about 10−3 ohm-m at 20° C.

### Claim 6 (depends on 1)

The electrode of claim 1, wherein the electrode active material comprises sulfur.

### Claim 7 (depends on 6)

The electrode of claim 6, wherein the electrode active material comprises elemental sulfur.

### Claim 8 (depends on 1)

The electrode of claim 1, wherein the binder comprises a polymeric binder.

### Claim 9 (depends on 8)

The electrode of claim 8, wherein the binder comprises polyvinyl alcohol.

### Claim 10 (depends on 1)

The electrode of claim 1, wherein the electrode has a porosity of at least about 40% and up to about 70%.

### Claim 11 (depends on 1)

The electrode of claim 1, wherein the thickness of the electrode is less than or equal to about 1 mm.

### Claim 12 (depends on 11)

The electrode of claim 11, wherein the thickness of the electrode is at least about 10 micrometers and less than or equal to about 1 mm.

### Claim 13 (depends on 1)

An electrochemical cell comprising the electrode of claim 1.

### Claim 14 (depends on 13)

The electrochemical cell of claim 13, comprising a second electrode comprising lithium.

### Claim 15 (depends on 14)

The electrochemical cell of claim 14, wherein the second electrode comprises lithium metal and/or a lithium alloy.