Production process for alkali metal-sulfur batteries having high volumetric and gravimetric energy densities

A process for producing an alkali metal-sulfur battery, wherein said alkali metal is selected from lithium (Li) and/or sodium (Na), said process comprising:

• (a) preparing a first conductive porous structure or first conductive foam layer;
• (b) preparing a second conductive porous structure or second conductive foam layer;
• (c) injecting or impregnating a first suspension into pores of said first conductive porous structure to form an anode electrode, wherein said first suspension contains an anode active material, a conductive additive, and a first liquid or gel electrolyte and wherein said anode electrode and said first conductive porous structure are of like shape and dimensions;
• (d) injecting or impregnating a second suspension into pores of said second conductive porous structure to form a cathode electrode, wherein said second suspension contains a cathode active material, a conductive additive, and a second liquid or gel electrolyte, wherein said cathode active material is selected from sulfur, lithium polysulfide, sodium polysulfide, sulfur-polymer composite, organo-sulfide, sulfur-carbon composite, sulfur-graphene composite, or a combination thereof;
• and wherein said cathode electrode and said second conductive porous structure are of like shape and dimensions;
• and
• (e) assembling said anode electrode, a separator, and a cathode electrode into said alkali metal-sulfur battery, wherein there is no drying to said anode electrode and no drying to said cathode electrode during said process.