Sulfur-based composite cathode-separator laminations and battery cells comprising the same

Abstract

Composite cathode-separator laminations (CSL) include a current collector with sulfur-based host material applied thereto, a coated separator comprising an electrolyte membrane separator with a carbonaceous coating, and a porous, polymer-based interfacial layer (PBIL) forming a binding interface between the carbonaceous coating and the host material. The host material includes less than about 6% polymeric binder, and less than about 40% electrically conductive carbon, with the balance comprising one or more sulfur compounds. The PBIL can have a thickness of less than about 5 μm and a porosity of about 5% to about 40%. The host material can comprise less than about 40% conductive carbon (e.g., graphene) and have a porosity of less than about 40%. The carbonaceous coating (e.g., graphene) can have a thickness of about 1 μm to about 5 μm. The CSL can be disposed with an anode within an electrolyte to form a lithium-sulfur battery cell.

Dependencies are inferred from the claim text.